JPS5936760A - Tufted 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 tufted carpet using a synthetic fiber multifilament composite bulky crimped yarn as a pile yarn having a spun-like feel and outer wafer.

In recent years, in Japan, a wide variety of carpets have come into use in response to the increasing fashion and diversification of interior design as lifestyles become more Westernized. Among these, tufted carpet has the highest productivity among carpet manufacturing methods, and has become the mainstream carpet. However, the appearance of conventional tufted carpets, especially the hue and pile form, tends to be monotonous and uniform, and lacks a sense of fashion or luxury. Research and development of a new patterning device is underway.

On the other hand, Jillk textile multifilament crimped yarn (B
Carpets using CF) as pile yarns are particularly durable and widely used compared to those using spun yarns as pile yarns, but carpets using multifilament crimped yarns as pile yarns are It lacks the soft texture and feel of a carpet made of pile yarn, and its uses are limited. In addition, cut pile carpet using multifilament crimped yarn as pile yarn has the problem that each filament comes apart during the tafinder Φ dyeing, backing, etc. process, and the carpet tends to become fel-like. There is also. In order to prevent this, it is known that the crimped yarn is heated and heat-set to give it convergence and is used as pile yarn, but it has the disadvantage of being expensive. .

The inventors of the present invention have conducted intensive research to solve the above-mentioned drawbacks of Toughnut Carpet, which uses conventional synthetic fiber multifilament crimped yarn (BCF) as pile yarn. The present invention was achieved by discovering that by tufting the yarn into a base fabric, a spun-like toning pet that is luxurious and fashionable can be obtained.

Accordingly, the present invention provides a synthetic fiber multifilament yarn consisting of a core capable of retaining stress and a fiber having a large number of minute loops, in which the fibers constituting the composite yarn are individually separated. has a Sz silane crimp, and has a single fiber fineness of 5 to 50 denier (DE) and a total fineness of 500 to 10.
This is a spun-like stylish tufted carpet characterized by tufting a new synthetic fiber multifilament composite yarn of 000de as pile yarn to the base fabric.

In the tufted carpet of the present invention, the synthetic fiber multifilament yarn constituting the composite yarn serving as the pile yarn is a general term for multifilament yarn made of thermoplastic synthetic polymers such as polyamide, polyester, polyolefin, polyacrylonitrile, polypropylene, etc. However, multifilaments such as polyamides, polyesters, and polypropylene are suitable.

Two or more single-filament synthetic fiber multifilament yarns forming the core and sheath of the composite yarn may also contain different types of synthetic fibers as materials for part or all of the core or sheath. Furthermore, original finger yarns or dyed yarns of the same or different types of synthetic fibers may be used in combination. These single thread synthetic fiber multifilament yarns are synthetic fiber multifilament yarns).
i1 yarn (BCF), the total fineness is usually 1
It is used in the range of 00 to 3000 de.

The shape of each filament is triangular or square.

A non-circular shape such as a trilobal shape, a Y-shape, a cross shape, etc. is preferable, and the filament may have one or more continuous hollow portions in the longitudinal direction of the filament. Further, the multifilament yarn may be a mixture of filament yarns of 21-Jf or more having different Lii yarn deniers, gii surface shapes, dyeability and/or dyeing rates; It may also contain isoelectric filaments.

Here - Ba [dyeability 16yo / Yota is dyeing rate Sk
i, cro2(・11 or more) means that the parent A1 [1 for a certain tdi dye differs depending on the filament's 1ifi 'x!
If dyed, the other one is dyeable to 1% or 2%), and the dye absorption capacity differs depending on the filament's fffla (for example, one is light dyeable and the other is dark dyeable). ), or have both of these characteristics.

The synthetic fiber multifilament condensable yarn constituting the carpet pile yarn of the present invention consists of a core capable of retaining stress and a sheath having a large number of minute loops, and the fibers constituting the composite yarn are individually Has Sz silane crimp. .

Constituent single fibers of two or more single-filament multifilament yarns forming the core and sheath of the composite yarn are mixed and intertwined with each other, and a large number of fine particles are formed in the single-filament multifilament yarn of the sheath. It forms loops, but if the number of loops is too small, the span-like texture will be poor.
If it is too large, the tufting properties tend to be poor, so 100
Approximately 0 to 10,000 pieces/m is preferable. On the other hand, if the loop size is too large, it may be a factor in reducing the tufting properties, so the maximum loop size is preferably 10 mm or less.

In addition, in order to obtain a carpet with volume and a soft texture, the fibers constituting the composite yarn must be individually
There are 8 bags having z crimp crimp 1), and the degree of crimp is preferably within the range of 3 to 15 in terms of the total crimp rate of the yarn. If the crimp h'-total fold ratio is less than 3 inches, not only will the carpet not be cushiony, voluminous, or dull, but the bulkiness of the pile yarn will be poor, leading to poor curling and cost disadvantages. So I don't like it. On the other hand, the limb has a total crimp rate &i:, I--C
If it exceeds ls%, not only will it have a rough and hard texture, but also, especially on cut pile carpets, the pile tip will come apart and the pencil point will deteriorate. This is not preferable because A becomes a form.

In addition, here - [number of loops] "maximum loop - size of 7 - 1 and 1 total crimp rate" are as follows, respectively < 1
6i11 A'H) with the specified value.

Collect 1 m of Eft of 1 shi: d of the loop I/shi composite yarn, and count the number of loops that protrude outside from the thread weave 1111 using the projection method. Repeat this operation 10 times. Let the average value be the number of loops.

Maximum Loop Size Take 1 rIL of an arbitrary part of the composite yarn, measure the height of the loop protruding outward from the yarn surface using a projection method, and take the maximum value as the maximum loop size.

Total crimping rate (TO) Total crimping rate (TC) indicates the degree of crimp (crimping) of the yarn.A composite yarn is taken out from the cheese to a length of about 1 m, and 0, 1. The sample length lO was measured after 1 minute under p/de Bojing, and the sample was dehydrated by developing crimp in boiling water for 30 minutes in a free state, and then air-dried for one day and night under standard conditions. , measure the length l after 1 minute under a load of 1 g/da, then measure the trial length 12 after 1 minute under a load of zq/de after leaving it free for 3 minutes, and measure these measured values. The total crimp ratio (TO) is calculated from the following formula.

TC (饅) =, =

In other words, the $ f & fiber fineness (de) of the composite yarn is preferably in the range of C5 to 5 oae depending on the texture of the carpet, and if it is less than 5 de, cushioning properties are obtained.

This is not desirable because it results in a carpet with no repellency, and if it exceeds 50 DE, it results in a carpet with an alin or texture. The total fineness is 1!1 compared to the tuft machine.
, 500~tooo in terms of (ease of tufting).

11・used in the range of de.

The multifilament drawn bulky yarn (composite yarn) having the five-layer characteristics described in 1111 can be manufactured by heating bIt body injection processing as described below, that is, by heating turbulent flow nozzle. (14 yarns to be fed are 1, 1, 2, 2, 11) with different degrees of intersection, 11)
-Do(]-Feed for speed to Ra It is preferable to supply the above IIt Itoei Multi-Flament yarn, and the heated fluid injection processing is carried out by a conventionally known method, for example, U.S. Pat. The method described may be adopted, but the temperature of the heated fluid in heated fluid injection processing is preferably 200 to 260 ° C. when the fluid is a desired temperature.
(If the fluid is super steam, the temperature is preferably 180 to 240°C. In such a strip f1, not only many minute loops are formed at the same time as the heated fluid crimps, but also the filaments mix with each other. The core overfeed is 4 or 10 to 100 inches based on the speed of the feed roller A at the time of heating fluid injection.
The draft rate after processing is preferably 5 to 35 inches.

The spunlike FA tufted carpet of the present invention can be produced by using a tufting machine with a gauge suitable for the total roughness, using the multi-finment composite co-high crimped yarn produced by the method described above as the pile yarn. The resulting carpet is made by tufting the base fabric according to the standards of There are many small loops lI'- on the surface of the part.
present, giving it a very spun-like feel and appearance.

In addition, the pile yarn of the tufted carpet of the present invention, the multi-filament/1 high-bulk crimped yarn, is generally used in the untwisted state to take advantage of the advantage that it can be manufactured at the lowest cost. , partial heating or 2 depending on the material.
More than one book may be combined and twisted.

On the other hand, the dyeing method may be a pre-dyeing method in which the dyed yarn is tufted using Space Dye Cheezer 1 or the like (or a reverse dyeing method in which the dyed yarn is tufted and then dyed).

The tufted carpet of the present invention as described above has the smoothest feel and appearance, and has the smoothest texture and appearance.
It is useful as a long-lasting, fashionable, high-class carpet.

Hereinafter, the method of the present invention will be explained in detail with reference to examples.Example 1 As shown in FIG.
850de/6B file) at a feeding speed of 450
At the same time, a cationic dye dyeable nylon 6 multifilament yarn (850 de/68 fits) with a triangular hollow cross section was fed to the feed roller at a feed rate of aoom/min, and then two Koei supplied from the feed roller is doubled and passed through the hot air turbulent jet nozzle described in Fig. 1 of Japanese Patent Publication No. 36-19223, so that the hot air temperature is 23.
0℃, 9/ct in hot air pressure cuff! The crimping process was performed under the following conditions: 60% core overfeed during processing, and a draft of 20 inches after processing.

The obtained nylon 6 multifilament composite bulky crimped yarn had the physical properties shown in Table 1 and had many small loops.

Table 1 Pile yarn physical properties This composite bulky crimped yarn was tufted with a loop pile tuffening machine at a gauge of 1710 inches, 8.5 stitches/inch, and a pile height of 5 WHm, and then acidified with a continuous dyeing machine. Dye Tectilon Yellow
w 4 R (manufactured by CIBA GEIGY) and cationic dye pAstrazon Blue 5GL (BAYER
(manufactured by Co., Ltd.) under the conditions of a steamer temperature of 100°C and a steam time of 5 minutes.

The obtained loop pile carpet has many minute loops on the pile surface as shown in Figure 1, and the appearance and
It had an extremely smooth feel and was of high quality with 1114 degrees of durability.

On the other hand, for comparison, regular type nylon 6 multifilament yarn (850de/68
ft1m) to the feed roller at a feeding rate of 4so@/min, at the same time, a nylon 6 multifilament yarn (850d
e/68 film) at a feeding rate of 2 Q Q @ 7
Then, the yarns fed from two types of feed rollers are combined and passed through a room temperature turbulent jet nozzle to produce a compressed pneumatic cuff kg/ol and core overfeed during force processing. The loop pile carpet that was processed under the conditions of 10 inches and processed plate draft 5-, and tufted and dyed under the same conditions as the above example, had many small loops on the pile surface.
The fibers constituting the pile yarn individually had Sz silane crimps, and were of poor quality with no cushioning properties or voluminous feel. In addition, a regular type nylon 6 multifilament yarn and a cationic dye dyeable type nylon 6 multifilament yarn (both of which have a triangular hollow cross section) were lined up and placed on a roller heated to 180°C. and then passed through a hot air turbulent jet nozzle at a hot air temperature of 230°C and a hot air pressure of 'jJ7 kg/C#! , overfeed 90% during machining, draft 40φ after machining, machining speed 45O @
Crimp processing was performed under the condition of 1/2 minute, and tufting was performed under the same conditions as in the above example.

The dyed loop pile carpet did not have minute loops formed on the pile surface, and therefore lacked a spun-like appearance and feel.

Example 2 The nylon 6 multifilament composite bulky crimped yarn of the present invention obtained in Example 1 was cut by a cutting machine with a gauge of 1/lO in-f-, a string (9 pieces/
inch, pile height 8 mg, tufting 1-1, and then dyeing using a continuous dyeing machine under the same conditions as in Example 1.

The resulting cut pile carpet is shown in Figure 2.The cut pile carpet has no sag (as shown in Figure 2), and there are many minute loops on the pile surface, giving it an extremely span-like appearance and feel. It was of high quality and excellent durability.

Example 3 The nylon 6 multifilament composite bulky crimped yarn of the present invention obtained in Example 1 was dyed with an acid dye Kayanol Yellow NFG (Nippon Kayaku Co., Ltd.) and a cationic dye Astrazon Blue 5 using a cheese dyeing machine.
Cheese dyeing was performed using GL (BAYER M) at 100° C. for 30 minutes, and tufting was performed under the same conditions as in Example 2.

As shown in Figure 2, the resulting cut pile carpet does not have any loose cut piles, and has many minute loops on the pile surface, giving it an extremely spun-like appearance and feel, and is very durable. It was of excellent high quality.

Example 4 Regular type nylon 6 multifilament crimped yarn with trilobal cross section and trilobal cut r*+-c
Cationic dye dyeable type nylon 6 multifilament crimped yarn (all 1000 de;/s 6 fils)
) are aligned and fed to the feed roller at a feeding speed of s o Om/min.
ilg) was fed to the feed roller at a feed speed of 260 m/min, and then the yarn was fed from the feed roller at 2 kV and I+ for 1 yen! The three yarns were passed through a doubling yarn L and a hot air turbulent jet nozzle, and subjected to crimping under the same conditions as Example 1.

The obtained multifilament composite bulky crimped yarn had the properties shown in Table 2 and contained many minute loops.

Table 2 Pile yarn physical properties This composite bulky crimped yarn was processed using a loop pile toughening machine with a gauge of 5732 inches and 8 stitches/inch.
Tufting at 6 pile heights and then 60 °C at 95 °C using the same dye as in Example 1 in Wins dyeing machine.
It went up for a minute.

As shown, the resulting loop pile carpet had many minute loops on the pile surface, had an extremely spun-like appearance and feel, and was of high quality with excellent durability.

[Brief explanation of drawings]

Fig. 1 is an enlarged side view of the main part showing an example of a pile carpet with loops leaked by the method of the present invention, and Fig. 2 is an enlarged side view of the main part showing an example of a cut pile carpet obtained by the method of the present invention. Figure 3 is an enlarged schematic diagram of the cross section of the triangular hollow fiber. 1 is a base fabric, 2 is a pile yarn, 3 is a minute loop, and 4 is a hollow part.

Claims (1)

[Scope of Claims] 1. A composite yarn consisting of a core capable of retaining stress and a sheath having a large number of tight loops, in which the fibers constituting the chain plate composite yarn are individually Sz rank crimped. has
And single fiber fineness is 5 to 5 () denier, total fineness is 500
A tufted carpet characterized in that it is tufted onto a base fabric as a composite yarn pile yarn of ~10,000 denier. z +i The tufted carpet according to claim 1, wherein the fibers constituting the yarn are made of polyamide, polyester, or polyolefin.