JPS6047949B2 - Velor style cutlet carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a velor-like cut carpet that has good texture and quality and is highly durable.

Conventionally, spun yarns such as acrylic, nylon, and wool are used as pile yarns for velor-like cut carpets having a pile length of 4 to m.

However, spun yarns have the disadvantage that they shed hair, and no matter how many times they are cleaned, the hair loss does not stop. In addition, since spun yarn has twists, 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. There are drawbacks. On the other hand, a velor-like cut carpet whose pile yarn is a multifilament crimped yarn (BCF) composed of monofilaments having S, Z twists and random clips along the filament axis length, Because of this structure, there is no problem of shedding like with spun yarn.

However, when the pile yarn density becomes low, such a carpet loses its stiffness and has a poor feel, tends to become felt-like, and has poor durability due to crimping. The present inventors used multifilament crimped yarn (BCF) to create a robust velor-like cut carpet that does not have the above-mentioned drawbacks and has excellent texture and quality even though the pile yarn density is lower than conventional ones. As a result of intensive research, it was discovered that the desired tongue 5A style cut carpet could be obtained by using a special revealed 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 random S, Z twists and crimps along the filament axial length, which has a total crimp rate of 3 to 10% and a crimp fastness. is 70% or more, the actual crimp ratio is 5% or more of the total crimp ratio, and there is no substantial twist in the filament group constituting the crimp ratio, and the degree of interlacing is 1 to 10 strands/m. An overt crimped yarn made of thermoplastic synthetic multifilament is used as the pile yarn, the cut pile length is 4 to 15 Tr0n1, the number of piles is 3 or more per 1 cm in both length and width, and the pile yarn density is 1000 g/j1' or less This is a velor-like cut carpet that is characterized by: 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 6, or copolymers thereof, are particularly suitable; The total denier of the filament is preferably 600 to 6000c1e, and the single yarn denier is preferably 6 to 31e.

The filament cross-sectional shape of each single yarn increases crimp rigidity,
In order to create a sense of volume due to bulkiness, Y-shape, trilobal, or cross shapes are preferable, and filament having a triangular or square cross section with a hollow portion inside may also be used. Said pile yarn is a three-dimensional non-helical conventional multifilament crimped yarn (B
Although it belongs to the CF) classification, it has the following unprecedented characteristics. Looking at the crimp characteristics, the total crimp rate (TC) is in the range of 3 to 10%.

When the total crimp rate exceeds 10%, the velour-like cut carpet using the crimped yarn as the pile yarn becomes felt-like. This is because when creating a cut carpet, one end 3 of the crimped yarn is cut and a group of filaments becomes free, and when the crimp occurs during the heat treatment during dyeing, the filaments become entangled, and the surface of the carpet is This is because the tip of the crimped filament (pile) in the part where it bends freely and becomes felt-like. 41 When the crimp ratio is set to 10% or less, entanglement of filaments due to heat treatment will be reduced,
The ends of the crimped filaments no longer bend, resulting in a carpet with firmness and good texture.

However, when the total crimp rate is less than 3%, the quality of the velor-like cut carpet that can be obtained is inferior because the voluminous volume caused by crimp is eliminated. In other words, the total crimp rate is preferably 3 to 10%, and preferably the da is 4 to 8%.

Moreover, the crimp fastness is 70% or more.

Here, crimp fastness is an index indicating the thermal stability of crimp in boiling water, and can be used to judge the degree of rigidity of crimp. That is, by applying a load of 5 mg/De to the crimped yarn,
This is the ratio of the residual crimp rate after treatment with boiling water to the crimp rate of the crimped yarn treated with boiling water without any load, expressed as a percentage.
The larger this value is, the more robust the crimp is. In other words, high crimp fastness indicates that the crimped yarn has been sufficiently heat set during production. Velour-like cut carpets that use crimped yarns with a crimp fastness of less than 70% as pile yarns are weakly heat-set when dyed, so the crimps become loose during dyeing, the waveform becomes coarse, and the filaments also stick together. They tend to get tangled and form a felt-like appearance.

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 tend to bend, which promotes felting. This phenomenon occurs even if the crimp rate is low, but if the crimp fastness is 70% or more (preferably 80% or more), that is, if the heat setting is sufficient, crimp will occur due to the heat treatment during dyeing. However, changes in the form of crimping are less likely to occur. Setting the crimp fastness to 70% or more means that the pile yarn density in the cut carpet is 10%.
This is important when the yarn density is as low as 00 g/d or less, especially from 500 to 650 g/d, and is an essential requirement for obtaining a product with good quality and texture at a low pile density.

By the way, multifilament crimped yarns generally develop crimps during dyeing and heat treatment after dyeing, but in order to completely eliminate the felting of carpets, it is necessary to change the crimp rate by heat treatment to change the crimping form. It is important to reduce the amount of pile yarn, and from this point of view, in the present invention, an exposed type crimped yarn is used as the pile yarn.

According to the research conducted by the present inventors, the actual crimp rate determined by the method described below is 50% or more (preferably 60% or more) of the total crimp rate.
Yes, and the crimp fastness mentioned above is 70% or more F (preferably 80%
% or more), even if the pile yarn density is relatively low, almost no felting will occur, resulting in a velor-like carpet with good quality and texture. Pile yarn density is important for velor-like cut carpets, and ordinary spun yarn has a density of 100.
If it is less than 0 g/Trl, the pile spacing becomes large and the quality of the carpet deteriorates, and the pile yarns tend to fall down, resulting in poor texture and loss of durability. However, the multifilament crimped yarn of the above-mentioned overt crimp type can be obtained with good quality and feel at a pile yarn density of 500 g/I or more. In this case, in order to maintain good quality and feel at a relatively low pile yarn density of about 500 to 650 g/d, it is necessary that the crimped yarn has no substantial twist. Note that 1 substantial twist here means a twist of approximately 3 leaves/m or more that is actively heated during the twisting process, and twists that occur during the manufacturing process, such as twisting during winding, unwinding, twisting, etc. A twist of about 15 T/m or less that falls within the range corresponds to one substantial twist, and the presence of this degree of twist is permissible.

This is because the pile length of a velor cut carpet is 4~1C)m! n, such a low degree of twist as described above 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. Therefore, during tufting, the crimped yarn must have interfilament entanglement of 1 strand/m or more in terms of the interlacing degree described below. .

However, if the carpet has entanglement with an interlacing degree of 10 strands/m or more, cut piles with partially converging tips will become noticeable when used as a cut carpet, resulting in a decrease in quality. In other words, the degree of interlacing of the crimped yarn used as pile yarn must be in the range of 1 to 10 threads/m.
The degree of interlacing is preferably 2 to 5 lines/m. When such crimped yarns are used as pile yarns to construct cut piles and create velor-like cut carpets, the filaments constituting the pile yarns are entwined with each other, so there is no excessive restraint, and the pile yarns converge on the pile surface. There is no force at all, and the boundary between adjacent pile yarns becomes difficult to discern.

At this time, if the pile yarn density is less than 500 g/7, the pile spacing becomes large and the quality and feel are poor, so as already mentioned, the density needs to be at least 500 g/d. At this time, it is necessary to drive a large number of piles and to balance the vertical and horizontal directions.To obtain good quality, quality, and texture, it is appropriate to use at least 3 piles per 1cm both vertically and horizontally. It is preferable to implant 4 or more per 1 cm.

In addition, the shorter the pile length, the fewer gaps between piles, which is effective for creating a velor-like appearance, but if the pile length is too short, the texture of the carpet will be poor, so it is difficult to give a good texture. It is necessary to set the pile length to 4wIn or more.

On the other hand, when the pile length is 15 or more, the pile tends to fall down easily and loses its elasticity, resulting in poor texture. Therefore, the pile length is 4
The range is preferably from 15TIn to 15TIn. The velor-like cut carpet of the present invention as described above does not have the problem of shedding compared to those using conventional spun yarn, and has good quality and texture even with a low pile density. It has a much better texture than conventional multifilament crimped yarn (BCF), and has excellent durability without causing crimping or felting.

The velor-like cut of the present invention has such various advantages)
Carpets are characterized by the use of the above-mentioned special multifilament crimped yarns as pile yarns, and the method for producing the crimped yarns will be described in detail below. Generally, a crimped yarn (BCF) obtained by crimping a 5-multifilament yarn of a thermoplastic synthetic polymer such as polyamide using a heated fluid is a latent crimped yarn.

In other words, such crimp processing methods include 1 processing using turbulent flow of heating fluid, 2 processing in which the filament hits a barrier together with a laminar flow of heating fluid, and crimping processing using 3ζθ laminar flow of heating fluid. However, these are crimped filaments that are preheated and then subjected to intramolecular strain and intermolecular strain during the crimping process.
Latent crimped yarn 3 where intermolecular strain is relaxed and crimp occurs
5, and is characterized by a latent crimp rate of 50% or more of the total crimp rate. The overt crimped yarn used in the present invention is obtained by further heat-treating the latent crimped yarn as described above to develop crimps.
In other words, if heat treatment is performed in an unrestricted state such as a skein, the crimped yarn will develop crimps freely and will form a crimped filament even in the direction perpendicular to the fiber axis. Since the carpet is heat-set in a deformed state, when a velor-like cut carpet is formed, the end of the pile is bent and the texture is impaired.

On the other hand, if the relaxation heat treatment is performed while the fibers are constrained in the axial direction, crimping will occur, but the filament yarn will become crimped filaments extending in the fiber axial direction, resulting in the formation of a velor-like cut carpet. When this is done, there will be no bending of the pile tip and a good texture will be obtained. Here, methods for relaxing heat treatment in a restrained state include, for example, a method in which crimped threads are softly wound around the cheese and the cheese is heat set with a steam setter, or a method in which hot water at 80 to 100°C is circulated through the cheese. Examples include a method of heat treatment. When hot water is used as a heat treatment method such as the latter, dissolving the dye in hot water, circulating it, and heat treating it at the same time as dyeing (cheese dye) is the best way to obtain a good velor-like cut carpet. . In other words, with this kind of yarn dyeing, after the cut pile is formed, it will not be affected by the movement of the heated dye solution, and the cut pile can be formed in the ideal heat-set crimp state. Body O

Alternatively, as another heat treatment method, a method may be adopted in which a constant low tension of 0.05 g/De or less is applied between two rollers and the crimped yarn is restrained and then heat set with steam. Two of the crimped yarns heat-treated in a restrained state as described above.
After the total crimp rate becomes low and stable overt crimp occurs, even if heat treatment is performed after that, crimp only appears slightly, and the degree of interlacing also decreases. By heat treatment in this restrained state, it has an interlace degree of 1 to 10 ke/m,
In order to obtain an actual crimped yarn having a total crimp rate of 3 to 10% and a crimp fastness of 70% or more, the original latent crimped yarn should be 3 to 15 pieces/ It has an interlacing degree of m, a total crimp rate of 5-15%, and a crimp fastness of 5
It needs to be 0% or more, more preferably 4
It has an interlacing degree of ~103j/m, and 7~
It is desirable to have a total crimp ratio of 12% and a crimp fastness of 55% or more. 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 40° below the melting point, and then heating the drawn thermoplastic synthetic fiber in an overfeed region where the overfeed rate is 70% or less. Shrinkage and bulking processing is performed using a turbulent flow of heated compressed fluid, and then stretched in a draft area at a constant tension of 0.15 to 0.40 g/De to achieve a heat shrinkage rate of 15%.
It is manufactured by rolling it up under the above conditions.

Next, the degree of interlacing, total crimp rate, crimp fastness, potential crimp rate, actual crimp rate, heat shrinkage rate, etc. in the present invention will be explained in detail.

(1) Degree of interlacing The obtained multifilament crimped yarn was suspended according to the hook drop method described in US Pat. 2g/De), the single yarn group constituting the crimped yarn is divided in half, and the load is suspended in the direction in which the crimped yarn hangs.

Find the distance L that the load has moved. The same test was conducted five times and the average value [interlace (L) using the following formula]
Calculate degree. ″2) Total crimp rate, crimp fastness, potential crimp rate, actual crimp rate Take out a crimped yarn of a certain length and weigh 0.1g.
Yarn length E after 1 minute under a load of /De.

was measured, and then the load was removed, and after 3 minutes, the extension f1 was measured again after 1 minute under a load of 2 mg/De, and then the free state and the state with a load of 5 mg/De applied. After dehydrating the sample in boiling water to develop crimps, it was air-dried for one day and night under standard conditions, and then a load of 0.1 g/De was applied to the sample, and after 1 minute the lengths of each sample were E2 and e''. 2, then after leaving it for 3 minutes free, under a load of 2 mg/De, measure the lengths '3 and e''3 after 1 minute, and from these measurements, the total crimp rate, the actual crimp rate. The crimp rate, potential crimp rate, crimp fastness, etc. are calculated using the following formula. The present invention will be specifically described below with reference to Examples. Example 1300c made of nylon 6 (Tm=215 material C)
A drawn yarn having a trilobal cross section of 1e/68fi1 was supplied to a turbulent flow type heated fluid nozzle at a constant speed of 700111/min to perform heated fluid crimping.

Claims (1)

[Scope of Claims] 1. A multifilament crimped yarn composed of filaments having random S, Z twists and crimps along the filament axial length, the total crimp rate of which is 3 to 3.
10%, the crimp fastness is 70% or more, the actual crimp rate is 50% or more of the total crimp rate, and there is no substantial twist in the constituent filament group of the crimp rate, and 1 to 10 pieces/ An overt crimped yarn made of thermoplastic synthetic multifilament with an interlacing degree of m is used as the pile yarn, the cut pile length is 4 to 15 mm, and the number of piles is 1 c in both length and width.
3 or more threads per m, and pile density is 1000g/m
A velor-like cut carpet characterized by a size of ^2 or less. 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. 3 Multifilament crimped yarn has a total denier of 600 to 6
The velor-like cut carpet according to claim 1 or 2, which is a multifilament crimped yarn with a single yarn denier of 000 de and a single yarn denier of 6 to 30 de.