JPS5891860A - Velour-like cut carpet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a velor-like cut carpet that has good fit and quality, is excellent in durability, and is suitable for use as a low basis weight car mat carpet.

Conventionally, the pile length was 4 to 10. For the velor-like cut carpet of , spun yarns such as acrylic, nylon, and wool are used as pile yarns.

However, spun yarn has the disadvantage that hair loss occurs and the hair loss does not stop no matter how many times it is cleaned. In addition, since the spun yarn is twisted, the yarns are converged, and in order to obtain a velor-like carpet with good texture and quality, it is necessary to increase the density of pile yarn, which increases manufacturing costs. On the other hand, velour-like cut carpets are made of multifilament crimped yarn (BOF) i-pile yarn, which is made of monofilaments with S, Z twists and random curls along the filament axis length. Since it is made of curly yarn, it does not have the problem of shedding like spun yarn. However, when the pile yarn density of such a carpet becomes low, the surface of the carpet deteriorates, the carpet loses its stiffness, resulting in a poor feel, and the carpet becomes crimped, resulting in poor durability.

The present inventors have developed a velor-like cut suitable for car mats that uses multifilament crimped yarn (BOF) and has excellent texture and quality without the above-mentioned drawbacks even if the pile yarn density is lower than conventional ones. As a result of intensive research to provide a carpet 1, it was discovered that the desired velor-like cut carpet could be obtained by using a special latent crimped yarn as the pile yarn, and the present invention was achieved.

That is, the present invention is a multifilament crimped yarn composed of monofilaments having a filament axis length of KG, a random SIZ twist, and a crimp, with a total crimp rate of 8 to 14 inches, and a crimp fastness of 20 inches. ~40%,
A latent type winding made of a thermoplastic synthetic multifilament having an actual crimp ratio of less than 50, no substantial twist in the filament group constituting the crimped yarn, and an interlacing degree of 1 to 10 strands/m2. This is a velor-like cut carpet characterized by using silk yarn as pile yarn. The present invention will be explained below with reference to the drawings.

1 to 3 are schematic cross-sectional views of carpets, in which FIG. 1 shows one embodiment of the present invention, and FIGS. 2 to 3 show comparative examples.

The pile yarns constituting the velor-like cut carpet of the present invention are made of thermoplastic synthetic multifilaments, and multifilaments made of polyamides such as nylon 6, nylon 66, or copolymers thereof are particularly suitable; The total denier of is 600
~2000 de is preferable, and the single yarn denier is 15~3
Qde is preferred. The filament cross-sectional shape of each single yarn increases crimp rigidity and creates a sense of volume due to bulk.
Y-shaped, trilobal, or cross-shaped filaments are preferred, and triangular or quadrangular filament cross sections with a hollow portion inside may also be used.

The pile yarn mentioned above belongs to the conventional multifilament crimp yarn (NAP) O classification of three-dimensional valve spiral with random S, z-twist and random curl dripping in the filament axial length in its shape, but with the following: There are things that have properties that have never existed before.

First, looking at the crimp characteristics, the total crimp ratio (TO) is 8.
It is within the range of ~14%.

When used as a BOF multifilament wound yarn kebile yarn with a total crimp rate of 8 to 14% according to the present invention, each single yarn of the 5-pile yarn has an appropriate ring, and while creating a moderate amount of entanglement between the single yarns, A cut carpet with good volume and coverage can be obtained without giving a felt feel (see Fig. 1).

On the other hand, when the total crimp rate exceeds 14%, a velor-like cut carpet using such crimped yarns as pile yarns becomes felt-like after piece-dyed (see Figure 2). This is because when creating a cut carpet, one end of the crimped yarn is cut and the filament group becomes free, and when the crimp occurs during the heat treatment during dyeing, the filaments become entangled, and the surface of the carpet is formed. crimped filament (pile)
This is because the tip of the material bends freely and becomes felt-like.

When the content of crimped yarn is 14% or less, entanglement between filaments due to heat treatment is reduced, and the tips of the crimped filaments do not bend, resulting in a carpet with firmness and good texture. However, when the total crimp rate is less than 8%, the crimp of the single fibers is low due to the low crimp ratio, and the resulting velor-like cut carpet loses its voluminous feel and is inferior in quality. (See Figure 3).

Moreover, the crimp fastness is 20 to 40%. Here, crimp fastness is an index indicating the thermal stability of crimp in boiling water,
This can be used to judge the degree of firmness of the crimp, and is a guideline for the crimp waveform of the -plane filament. In other words, it is the ratio of the residual crimp rate after applying a load of 5 q/de to the crimped yarn and treating it with boiling water to the crimp rate of the crimped yarn treated with boiling water without load M, expressed as a percentage. υ, the larger this value is, the more robust the crimp is; on the other hand, the smaller this value is, the rougher the waveform of the crimped filament is, improving the coverage of the resulting pile yarn on the carpet.

Velour-like cut carpets that use crimped yarns with a crimp fastness of less than 20% as pile yarns have a weak heat set when dyed, so the crimps become loose and the waveform becomes too coarse during one dyeing process. , the filaments become entangled and become too felt-like. Furthermore, the crimped filaments tend to become entangled due to forces such as the movement of the dye solution during dyeing, and the crimped filaments (pile) on the surface of the carpet in particular tend to bend, promoting felting.

On the other hand, if the crimp fastness exceeds 40%, the crimp waveform of the crimped yarn will be too fine and the coverage of the resulting pile yarn on the carpet will be poor. When observed, the base fabric is visible and the appearance is poor.

When the crimp fastness is 20 to 40%, the crimped waveform of the crimped yarn is moderately coarse and the coverage of the pile yarn is good,
It can brighten up low weight car mat carpets.

Setting the crimp fastness to 20% to 40% in this way means that the pile yarn density in the cut carpet is 300% to 800%.
2/W? This is particularly important when the yarn density is as low as 300 to 5 oor/rs, and is an essential requirement for obtaining good quality and texture at low pile density.

By the way, in the present invention, a multifilament crimped yarn having an actual crimp rate of less than 50% is used.

Multifilament crimped yarns with an apparent crimp rate of 50% or more have loops, walnuts, etc. in the yarn, making it difficult to tuft ≠ 4, and the cutting performance is poor when cutting loop piles, resulting in poor carpet quality. 's eyes become worse. In addition, since the crimp is sufficiently developed before the carpet is formed, the coverage of the pile yarn may be insufficient in low basis weight carpets.

The actual crimp rate is less than 50% (for latent crimp type crimped yarns,
Since there are few loops and walnuts, the tufting and cutting properties are good.When the resulting low basis weight carpet is post-dyed, the pile yarns develop crimps and the filaments that make up the pile do not stand upright, but in random directions. This results in a somewhat felt-like state with extremely good covering properties.

In addition, for velor-like cut carpets, the pile yarn density is required to be M, and for ordinary spun yarns, if the density is less than 800 f/m', the pile gap becomes large, the quality of the carpet deteriorates, and the pile yarns collapse. Because it becomes soft, the texture is inferior and durability is lost. However,
The above-mentioned latent winding type multifilament crimped yarn is 3oo
Good quality and feel can be obtained with a pile yarn density of r/m' or more. In this case, in order to maintain good quality and feel at a relatively low pile yarn density of about 300 to 800 t/FF11, it is necessary that the crimped yarn has no substantial twist.

In addition, "substantial twist" as used herein means a twist of approximately 3oT/m or more that is actively heated during the yarn twisting process, and is caused by twisting during winding, unwinding, twisting, etc. during the manufacturing process. A twist of about 15 T/m or less does not correspond to "substantial twist," and the presence of this degree of twist is permissible.

This is because the length of the pile in a velor-like cut carpet is 4 to 10 g, so with the low twist as described above,
This is because it does not bring convergence to the cut pile.

However, if the multifilament crimped yarn has no convergence at all, the tufting properties will be poor. is necessary. However, if the interlace L is more than 10 r/m, M
As a result, when a cut carpet is made, cackles with partially converging ends become noticeable and the quality deteriorates. Toe 9: The interlacing degree of the crimped yarn used as the pile yarn must be in the range of 1 to 10 strands/m, preferably 2 to 5 strands/m.

When such a crimped yarn is used to create a cut pile to create a velor-like cut carpet, the filaments that make up the pile yarn are not constrained by entanglement with each other, and there is no convergence of the pile yarn on the pile surface. The boundary between adjacent pile yarns becomes difficult to distinguish. At this time, if the degree of yarn yarn m is smaller than aoot/y, the pile gap will be large.
, quality and texture are inferior, so as already mentioned, the density needs to be at least 300 f/m'.

At this time, it is necessary to increase the number of piles and balance the vertical and horizontal piles.To obtain good quality and texture, it is appropriate to use 25 or more piles per 10 in both the vertical and horizontal directions. Therefore, it is preferable to implant 4 or less per 1α.

Also, the shorter the pile length, the fewer gaps between the piles.
Although it is effective in creating a velor-like appearance, if the pile length is too short, the feel of the carpet will be poor, so in order to give a good feel, it is necessary to make the pile length 4u or more. On the other hand, when the pile length exceeds 15M, the pile tends to fall down, loses its elasticity, and has a poor texture. Therefore, the pile length is 4 to 15. It is preferably within the range of .

The velor-like cut carpet of the present invention as described above does not have the problem of hair shedding compared to those using conventional spun yarns, has excellent coverage of the pile yarn even when the pile density is low, and has good quality. It has a texture. The velor-like cut carpet of the present invention, which has such various advantages, is most characterized by the use of the above-mentioned special multifilament crimped yarn as the pile yarn.

Such a latent crimped yarn is generally a crimped yarn (BOF) obtained by crimping a multifilament yarn of a thermoplastic synthetic polymer such as polyamide using a heated fluid. In other words,
Such crimping methods include: ■ Processing using turbulent flow of heating fluid, ■ Processing in which the filament is hit against a barrier with laminar heating fluid, and ■ Indentation processing using no-flow heating fluid. After preheating the filament...
1. During the crimping process, the yarn is crimped by applying intramolecular and intermolecular strain, so by heat treatment, the intramolecular and intermolecular strain is relaxed and it becomes a latent crimped yarn in which crimping occurs. It is indicated that the % total crimp rate is 5u% or more of the total crimp rate.

The manufacturing method for obtaining the latent crimped yarn includes preheating the drawn thermoplastic synthetic fiber at a temperature ranging from 40°C to 10°C below the melting point, and then subsequently increasing the overfeed rate to 70%.
In the following overfeed area, shrinkage and bulking processing is performed using a turbulent flow of heated compressed fluid, and then in the draft area, stretching is carried out in the range of O1513- to 0.4Qf/de and at a constant tension to determine the heat shrinkage rate. Manufactured by winding under conditions where the ratio is 15% or more.

Next, the degree of interlacing, total crimp ratio, crimp fastness, Iv existing line shrinkage ratio, actual crimp ratio, heat shrinkage ratio, etc. in the present invention will be explained in detail.

(1) Interlace degree According to the hook drop method described in U.S. Pat. Divide the single yarn group in half and suspend the load in the direction in which the crimped yarn hangs. A similar test is performed five times to determine the distance L that the load has moved, and the degree of interlacing (IL) is calculated from the average value using the following formula.

(2) Total crimp ratio, crimp fastness, crimp ratio in m, actual crimp ratio 14- A certain length of wound silk thread ft is taken out and the thread length after 1 minute under a load of α1+P/de is 1. Then, after 3 minutes after removing the load, the extension after 1 minute under a load of 2η/de was measured.1. After all measurements were taken, the free state and the 5wII/dc loaded state were rolled in boiling water for 30 minutes #1.
After expressing 1 and dehydrating it, it was air-dried for 1 day and night under standard conditions.
After that, a load of 0.1 f/de was applied to the sample, and the length t2r l-1 of each was measured after 1 minute.Then, after being left free for 3 minutes, the length after 1 minute under a load of 2 k/de was measured. Each length t3. Measure t3' and determine the total crimp rate and actual crimp rate from these measured values.

The potential crimp rate, the crimp fastness, etc. are calculated using the following formula.

Hereinafter, the present invention will be specifically explained with reference to Examples.

Example Nylon 6 (Tm = 215°C) was melt-spun and stretched to 1300 de/68 fi without being wound up.
After forming the drawn yarn with a trilobal cross-sectional shape of
The material was supplied to the crimping nozzle shown in Figure 1 of Publication No. 7339, and subjected to heated fluid injection processing at approximately 1600 de/
A crimped yarn of 68 fil was obtained.

The heating fluid (steam) pressure at this time is constant at 6.0 Kg/i. The thus obtained multifilament crimped yarn was tufted onto a base fabric and piece-dyed at a temperature of 98° C. for 30 minutes. Processing conditions, yarn quality, and carpet evaluation are shown in Table 1.

In addition, the texture of the carpet in Table 1.

The quality, volume and coverage were judged based on the following criteria.

<Wind> Sensory test by expert's touch υ.

○: Good, △: Meidou Kamimachi ×: Bad Product rank Visual inspection by an expert.

O: Good;

O: There is depth and the pile yarn has repulsive force.

×: There is a feeling of bottoming of the base fabric through the pile yarn.

Covering Properties> An expert observes the carpet surface from directly above and determines how easily the base fabric is visible.

○: Base fabric is not visible, good.

Δ: Practically possible ×: Base fabric is easily visible between pile yarns, defective.

17 - 12-

[Brief explanation of drawings]

1 to 3 are schematic cross-sectional views of a carpet, with FIG. 1 showing one embodiment of the present invention and FIGS. 2 to 3 showing a comparative example. l: pile yarn 2: base fabric = 19-

Claims (1)

[Claims] 1. Consisting of a filament with random S, Z twists and crimps along the filament axial length 7'
A multifilament twisted cotton yarn having a total sintering rate of 8 to 14%, a crimp fastness of 20 to 40%, and an apparent crimp rate of less than 50%, and in which the constituent filaments of the crimped yarn have a A velor-like cut carpet characterized in that a latent crimped yarn made of thermoplastic synthetic multifilament having no substantial twist and an interlacing degree of 1 to 10 strands/m is used as the pile yarn. 2. The velor-like cut carpet according to claim 1, wherein the multifilament crimped yarn is composed of polyamide filaments having a non-circular cross section. 1 Multifilament crimped yarn has a total denier of 600 to 2
The velor-like carpet according to claim 1 or 2, which is a multifilament crimped yarn with a single yarn denier of 15 to 3 odes. 4 The cut pile length is 4 to 15 m, the number of piles is 25 to 4 per 1 m in both length and width, and the pile thread density is 3.
00 to 800 f/m'.