JPS59216966A - Production of polyester 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 is a polyester multifilament crimped yarn (BC
F) This relates to a method for efficiently manufacturing a carpel tractor having stable bulkiness using e.

In recent years, as lifestyles have become more Westernized, carpets made of various materials with a wide variety of colors and patterns have come into use. The main materials used for these carpets include natural fibers such as wool and cotton, recycled fibers such as rayon cufra, and synthetic fibers such as polyamide, polyacrylonitrile, and polypropylene, but polyester fibers have excellent Despite these characteristics, spun yarns are only used to a small extent, and crimped polyester multifilament yarns are not used at all.

This is not because polyester fiber is unsuitable as a material for carpets, but because polyester has poor dyeability and polyester multifilament crimped yarn has high crimpability, when performing tufting, This is because it has the disadvantage of decreasing work efficiency.

In view of the above-mentioned current situation, the present inventors conducted various studies on methods of manufacturing carpets using polyester multifilament crimped yarns, and found that C and C, which make the crimp of polyester multifilament crimped yarns latent, It has been found that a highly stable/cure-resistant carpet can be produced efficiently under all specified heat treatment conditions after tufting.

The present invention has been made based on this knowledge, and involves tufting a carpet yarn made of polyester multifilament crimped yarn whose crimp potential rate (C) fully satisfies the following formula (1), and then subjecting it to heat treatment at J) and heat treatment time (
1) is characterized in that the heat treatment is performed under conditions that satisfy the following formula (2).

C20,7 (1) Raw yarn [i Shrinkage ratio: Expressed as the length of polyester multifilament crimped yarn under a load of 2 mg/d;

Total crimp rate: 1 for polyester multifilament crimped yarn
After applying a moist heat treatment at 30°C for 5 minutes, the length of the crimped yarn under a load of 2 mf/d is Ll, and the length under a load of 100 to 2 mf/d is L2, 1 200 (℃-min)≦TXt≦1000 ('C-min) (
2) However, 100eQ≦T〈Softening point of polyester (
Q: The non-inventive method will be explained in more detail below.

The composition of %1 of the method of the present invention is to tuft a specific carpet yarn, and the crimp potential rate (C) is C2.
It is necessary to tuft the entire carpet yarn consisting of a polyester multifilament crimped yarn of 0.7.

Here, the crimp potential rate (C) is, and the raw yarn crimp rate is 2 digits of the length of the crimped yarn under a load of 2 Mg/d. In addition, the total crimp rate is determined by applying a moist heat treatment to the crimped yarn at 130°C for 5 minutes, then measuring the length 'rL+ of the crimped yarn under a load of 2mf/d, and under a load of 100cm/d. It's afternoon.

In this case, if the latent crimp rate (Q) of the polyester multifilament crimped yarn is less than 0.7, the work efficiency during tufting will be significantly reduced, and the resulting carpet will have low bulkiness and inferior commercial value. It goes without saying that the potential rate (C) of two crimps is 0.7 or more, which is not preferable, and that C can be changed as appropriate depending on the type of carpet to be manufactured.

Although the total fineness of the polyester filament yarn used for this polyester multifilament crimped yarn may be any fineness, it is preferably selected to be 500 to 4500 d, and the single yarn fineness thereof is preferably in the range of 10 to 40 d. In this case, if the single yarn fineness is less than 10 d'f, there is a crimp effect, but the crimp becomes extremely fine, making it unsuitable as a yarn for carpets, and if it exceeds -40 d'f, the degree of crimping decreases. I don't like it. 1. The cross section of the polyester filament yarn may be a normal circular cross section, but the irregular cross section yarn with a degree of irregularity (diameter of circumscribed circle that intersects the filament cross section / diameter of inscribed circle) is 2.0 to 5 degrees. If this is the case, the crimp-producing effect of the present invention will be more pronounced.

Furthermore, it is also possible to use a spun-dyed yarn as the polyester filament yarn, and in this case, the carpet can have a clearer hue.

In order to obtain the polyester multifilament → crimped yarn in the method of the present invention, the polyester multifilament crimped yarn is wound with a high tension of, for example, 0.12 to 0.2 F//d or heat treatment at 50 to 80°C. This can be achieved through a turning process or by appropriately selecting the conditions for producing the entire polyester multifilament crimped yarn.

The method for obtaining the polyester multifilament crimped yarn used in the method of the present invention during its production will be described below.

The figure is a process schematic diagram showing one embodiment for obtaining a polyester multifilament crimped yarn used in the method of the present invention, in which the melt-spun polyester undrawn yarn (F) ff1l roller (1
) and the 10th roller (1), and the heated 20th roller (2) rotating at high speed. Main stretching is performed between the heated 30th roller (3) which rotates at a higher speed than 2).

In addition, the circumferential speed of the 30th la (3) is 1000 m/
If it is less than mn, it is economical in terms of productivity, and 11c25
If it exceeds 00 m/m1nf, the crimp development of the yarn will deteriorate, so it is preferably 1000 to 2500 m/min.

Note that in the 30th la (3), the yarn is preliminarily heated in order to effectively develop crimping in the subsequent crimping device, so the temperature of the surface product is 80 to 200°C, preferably 100 to 160°C. ℃
It is desirable to do so. Next, the above-mentioned drawn yarn 9
) is sent to a forced crimping device (4) using heated compressed air, where it is crimped. In the case of air, the fluid processing temperature in this crimping device (4) is preferably in the range of 200 to 300°C, and the pressure may be appropriately selected in the range of 3 to 10 kg/cm. Shrinked yarn (
F) is then sent to a cooling drum (5) where the yarn (F) is heated, and is rapidly cooled with cooling air on the drum (5). If the cooling temperature is too low, the final latent rate of crimp will be low; on the other hand, if the cooling temperature is too high, when the crimped yarn is unwound from the package, the crimps will recover and it will be difficult to form the desired latent crimped yarn. Therefore, the temperature of the cooling air should be set to 10 to 25.
Preferably, the temperature is cooled to .degree. The thus cooled yarn passes through the guide (6) to the 30th line (3) and the 3rd line (3).
It exits the take-up roller (7) while being re-buffed by the take-up roller (7) which rotates at a lower speed than the 0-ra (3).
The winding roller (9) is adjusted while adjusting the winding tension with the tensioner (8).
) is wound up in Eripackage tlG. Na2, @3
The overfeed rate of d between 0--7 (3) and the take-up roller (7) has a significant effect on the potential for crimp of the resulting carpet, and is an important factor governing the crimp. The overfeed rate is preferably 20 to 50%. In this case, if the overfeed rate is less than 20%, the crimp rate of the obtained crimped yarn will be low.
If it exceeds %, it becomes obvious and it is not good. In addition, if the winding tension is low, it is difficult to cause latent crimp yarn, whereas if it is high, there will be many broken yarns, which will hinder production. I P/d
It is preferable to set it as the range of. Thus, a polyester multifilament crimped yarn having a crimp potential ratio of 0.7 or more can be obtained using the method of the present invention.

The above-mentioned polyvarnish and chilled multifilament crimped yarns are supplied as carpet yarns as they are or twisted as necessary to form carpet yarns, and are supplied to a carpet manufacturing process and tufted into base fabrics such as nonwoven fabrics or slit yarns.

Since the carpet yarn made of the polyester multifilament crimped yarn of the present invention is made of the latent crimped yarn as described above, it has better workability during twisting and tufting than the conventional overtly crimped yarn. In addition, since there is no fatigue caused by crimp, it is possible to obtain a carperella with stable bulkiness.

Then, the second component of the method of the invention consists in a heat treatment, in which 200
It is necessary to perform the heat treatment under conditions that satisfy ('C, - minutes)≦TXt≦l 000 ('C-minutes). Here, T is the heat treatment temperature (Q, l 00 CCI≦T and the softening point of polyester (Q), and [ is the heat treatment time.

This heat treatment is a process that brings out the latent crimp of the carpet yarn mentioned above, and can be performed at any time after tufting. In this case, the product of heat treatment temperature and heat treatment time (TXt) is 200 to I U U O (-C・min)
400~900 ('
C・min) range is good.

If (TX t ) is less than 200 ('C-min), crimp is not sufficiently manifested, and if it exceeds 100 ('C-min), the crimp will be commensurate with the increase in (TXt). This is not preferable because it does not improve the yield rate and is not industrially economical, and the texture may become rough and hard. The heat treatment temperature ranges from 100 to the softening point of polyester (less than 0; if the heat treatment temperature is less than 100°C, the appearance of crimp will be significantly delayed; on the other hand, if the temperature is higher than the softening point of polyester, some yarns will fuse together). However, it is not preferable because the texture becomes rough and hard.The heat treatment temperature is 100 to 150°C and heat treatment for 5 to 10 minutes can make it sufficiently visible, but heat treatment at 130°C for 3 to 7 minutes is not preferable. Particularly preferred.The heat treatment may be either dry heat treatment or moist heat treatment, but since the carpet manufacturing process usually requires a banking process and post-processing, such as a molding process, the heat treatment may be performed using hot air in these and other processes. It is extremely economical to use dry heat treatment.

Thus, according to the method of the present invention, a carpet with excellent bulkiness can be manufactured easily and inexpensively.

The polyester used in the method of the present invention is a general term for polyesters containing ester bonds in the molecular chain, typified by polyethylene tere-7-thalerate, and also includes modified polyesters containing a third component such as inphthalic acid and paraoxybenzoic acid. .

As described above, the method of the present invention uses a polyester multifilament 4-crimped yarn with a latent crimp rate of 0.7 or more, tufts it, and then heat-treats it under specific conditions to make the crimp latent. Carpella to make the shrinkage obvious) t
Since the yarn is manufactured by JJ construction, the method of the present invention has better workability during twisting and tufting than conventional overtly crimped yarns, and also reduces crimping fatigue during these steps. Therefore, it is possible to manufacture carpets with stable bulkiness.

In addition, the method of the present invention can perform the heat treatment by fully utilizing the packing process or molding process,
Therefore, it can be produced industrially at low cost without requiring any extra steps. Furthermore, if a spun-dyed yarn is used as the polyester multifilament crimped yarn, carpets with a rich variety of colors and patterns can be manufactured, and the method of the present invention has extremely remarkable effects as an industrial manufacturing method. be.

Hereinafter, the method of the present invention will be specifically explained using examples.

Example Pigment (phthalocyanine green) total 0.5% during spinning
The undrawn yarn of polyethylene tele 7 which was added and mixed was fed to the 10th la in the step VC shown in the plan, and then pre-stretched ( Stretching ratio: 1.18), then 20th-La @3
After stretching at a stretching speed of 1800 m/m (stretching ratio 18.1) by changing the heating temperature of the 30th la between
``)' The crimping process is completed by changing the heating temperature using k, followed by rapid cooling with a cooling drum cooled to 20°C, and the overfeed rate is reduced between the 30th roller and the take-up roller. A polyester filament crimped yarn of 2000 d/96f was produced using the method of the present invention by changing the winding tension while overfeeding the yarn.This polyester filament crimped yarn of 130 T/M was twisted into carpet yarn. Then, tufting (gauge 1/LOG, level cut) was performed on a base fabric made of nonwoven fabric using a tufting machine (manufactured by Pitsunkaling Co., Ltd.).The tuft standard in this case was a pile height of 5 mm.

Stitch 24 st/10c+n, weight 0.3! ? /
It was lTl2. Next, this was subjected to dry heat treatment by changing the temperature and time of the dry heat treatment, thereby producing a carperator according to the method of the present invention.

On the other hand, for comparison, the latent rate of crimp was set outside the range of the method of the present invention, the heat treatment was set within the range of the method of the present invention, and the latent rate of crimp was set within the range of the method of the present invention, and the heat treatment was set within the range of the method of the present invention. Outside the scope of the process, a carpet was otherwise produced as described above.

The tufting efficiency and carpet bulkiness of these crimped yarns were investigated and the results shown in Table 1 were obtained. In addition,
The criteria for bulky properties were extremely good ◎ and good ○ according to the sensory test conducted by five evaluators.

Evaluation was based on a 4-level evaluation of poor (△) and extremely poor (×).

As is clear from Table 1 in the margin below, Sample 11 prepared by the method of the present invention
- 6 all had tufting efficiencies of 95% or more and good workability during tufting, and the resulting carpets had excellent bulkiness and stability.

On the other hand, sample layer 7 of the comparative example with a low crimp rate of 0.5 has poor tufting efficiency and bulkiness, and the product of heat treatment temperature and time is outside the range of the present invention. Sample layer 8. Although AIO had good tufting efficiency, Sample Layer 8 had poor bulkiness, and Sample A 10 had some fused threads and had a rough and hard texture. Furthermore, samples A9 and ill whose heat treatment temperature was outside the range of the present invention also had good tufting efficiency but poor bulkiness.

[Brief explanation of drawings]

The figure is a process outline/schematic diagram showing one embodiment for obtaining a polyester multifilament crimped yarn in the method of the present invention. 1...10th-La, 2...20th-La, 3
...30th-la, 4... crimping device, 5...
・Cooling drum, 6... Guide, 7... Take-up roller, 8... Tenser, 9... Winding-up roller,
10...Package, F...Yarn. Patent applicant Unitika Co., Ltd.

Claims (1)

[Claims] 1. A carpet yarn made of a polyester multifilament crimped yarn whose latent rate of crimp (Q) fully satisfies the following equation (1) is tufted, and then the heat treatment temperature (1) and the heat treatment time ( A method for producing a polyester carpet, characterized in that 1) is prohibited from heat treatment under conditions that fully satisfy the following formula (2): C≧0.7 (1) Raw yarn crimp rate; polyester multifilament crimped yarn The length under the load of 2■/d is expressed as 12 and 1.The length under the load of 1fCokeb-Akl, , ltJM/d is expressed as 12 and 1.Total crimp ratio: 1 for polyester multifilament crimped yarn
After heat treatment for 3'0'CXS, the length of the crimped yarn under a load of 2/d is Ll. When the length under a load of 100■/d is L2, 1 200 ('C-min)≦'rXt≦1000 ('C-min) (2) fc fr: L 100 CO≦T〈Softening point of polyester (Q2. A method for producing a polyester carpet according to claim 1, wherein the polyester multifilament crimped yarn is a dyed yarn. 3. A method for producing a polyester carpet according to claim 1, wherein the heat treatment is dry heat treatment. Production method.