JPS6343498B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a cut pile fabric using a novel focused thermoplastic synthetic multifilament crimped yarn as a pile yarn, and a method for producing the same.

In recent years, multifilament crimped yarn (so-called "BCF") made of thermoplastic synthetic polymers such as polyamide and polyester has been used as pile yarn.
The cut pile fabric, which is made by tufting the pile yarn onto a base fabric and cutting the formed loops to form a forest of pile yarns, can be used for carpets, mats, sheet fabrics,
It is widely used in the interior field such as upholstery for upholstery, and especially those with relatively long pile lengths are used as high-quality carpets such as Saxony and Sheaggy.

Conventionally, when making a cut pile fabric with a relatively long pile length using a multifilament crimped yarn as a pile yarn, the pile yarn is required to have cohesion (cohesiveness), so the multifilament crimped yarn has a thickness of 30 to 250T. Pile yarns that have been subjected to actual twisting of about /m and then heat set using steam, dry heat, etc. (so-called "set BCF") are used as pile yarns. However, such pile yarns require a twisting-heat setting process, resulting in low productivity and high manufacturing costs.Furthermore, after long-term use, the twist in the pile yarns tends to disappear and the cohesiveness tends to decrease. There's a problem.

For this reason, the present inventors first discovered that the constituent single yarns are partially fused to each other, S twist and Z twist exist alternately at random intervals in the length direction, and that the potential torque is 20 to 300 T/m. A cut pile fabric (cut pile carpet) made of multifilament crimped yarn with a total crimp rate of 5 to 15% is heat-treated in a free state by wind dyeing etc. to make the pile yarn spontaneously twist. proposed a method to express the
53-90376).

This method dramatically improves pile yarn productivity and significantly reduces manufacturing costs compared to the conventional "Set BCF" method, and the twist in the pile yarn disappears after long-term use. However, heat treatment such as win dyeing may twist or bend the single yarn at the tip of the pile yarn on the cut pile fabric, reducing the smoothness of the cut surface. . Shearing is generally performed to smooth the cut surface, but
If the single threads are twisted or bent, it is difficult to trim them uniformly, making it difficult to obtain high-quality products.

The inventors of the present invention improved the previous proposal and, as a result of intensive research in order to provide a cut pile fabric with even better quality, found that the total crimp rate is relatively small as a pile yarn, and the fabric has substantial latent torque. We have discovered that by using a special focused thermoplastic synthetic multifilament crimped yarn, it is possible to obtain cut pile fabrics with superior cut surface smoothness and superior quality compared to those previously proposed, and have developed the present invention. It has been reached.

That is, the present invention provides a cut pile fabric in which tufted pile yarns stand on a base fabric, in which the pile yarns (a) have a crimp of 3 to 10% in terms of the total crimp rate, and (b) have a constituent monomer. The yarns are partially fused to each other, (c) S twist and Z twist exist alternately at random intervals in the length direction, and (d) the potential torque index is
It is characterized in that it is composed of a focused thermoplastic synthetic multifilament having a tensile strength of 20 T/m or more and less than 60 T/m.

Hereinafter, the cut pile fabric of the present invention will be explained in detail with reference to the drawings.

Fig. 1 is a partial enlarged view schematically showing the cross section of the cut pile fabric of the present invention, and Fig. 2 is a focused thermoplastic composite multilayer with latent torque proposed by the present inventors in Japanese Patent Application No. 53-90376. FIG. 2 is a schematic partial enlarged view showing a cross section of a cut pile fabric using filament crimped yarns as pile yarns, which is heat-treated in a free state by win dyeing or the like to develop real twist in the pile yarns.

In FIGS. 1 and 2, 1 is a base fabric, 2 is a pile yarn tufted and cut from the base fabric 1, and 3a and 3b are single yarns at the tips of the pile yarns. In the cut pile fabric of the present invention, the pile yarn 2 has moderate convergence as shown in Fig. 1 by partially fusing the constituent single yarns and alternating twists in which S twists and Z twists are alternately present at random intervals in the length direction. It is composed of a multifilament crimped yarn (hereinafter sometimes abbreviated as "bundled crimped yarn") that has been imparted with properties (cohesiveness). The bundled crimped yarn has a total crimp rate of 3 to 10%, preferably 4 to 8%, as described below.
%, and has substantially no latent torque, and has a latent torque index of 20 T/m or more and less than 60 T/m.

"Partially fused" here refers to a state in which some of the filaments that make up the crimped yarn are incompletely fused, and the entire yarn is strong enough to be integrated. Rather than fusion, it simply refers to a state in which partial fusion occurs randomly to the extent that the cohesion (cohesiveness) of the entire thread is maintained, and it is bundled as a single thread, and is called "alternate twist". This is because partial fusion occurs in the twisted state due to the false twist fusion process described below, and the fused portions exist randomly in the crimped yarn in the untwisted state, so when untwisting, there is an opposite effect commensurate with the untwisted yarn. It is said that the twist in the direction is applied as if it were over-untwisted, and as a result, S-twist portions and Z-twist portions exist alternately at random intervals in the length direction of the crimped yarn. In addition, "potential torque" is calculated by leaving one end of the multifilament crimped yarn free and treating it in wet heat or dry heat, so that the yarn rotates by itself due to the torque, and as a result, the actual twist occurs spontaneously. The magnitude of the torque is expressed by the "potential torque index" measured by the method described below.

A pile yarn made of a bundled thermoplastic synthetic multifilament crimped yarn that has been given cohesiveness by partially fused and alternately twisted can be produced by selecting the degree of partially fused and alternately twisted to achieve the agglomeration described below. A coefficient of 5 to 100, preferably 20 to 60 is suitable. Since such pile yarn 2 has good bundling properties and is bundled so that the thread cross section is approximately circular, it has good handling properties, especially tufting properties, and the cut pile fabric has excellent pencil pointability after being cut. ing. Furthermore, this pile yarn 2
As shown in the figure, since the single yarn 3a at the tip is upright, the cut surface can be finished smoothly by shearing.

However, if the potential torque index in the pile yarn 2 is
If the yarn is over 60T/m or has a total crimp rate of over 10%, the single yarn is likely to twist or bend, making it difficult to finish the cut surface smoothly, and the total crimp rate is less than 3%. The bulk of the pile yarn is poor and the texture of the cut pile fabric is deteriorated.

Since the pile yarn 2 has single yarns that are partially fused as described above, the texture tends to be a little rough and hard. Therefore, it is preferable to soften the texture by setting the average single yarn denier to 15 de or less. However, if the average single yarn denier is smaller than 3de, the texture will be too soft and the waist will be lost.
15 de, especially 5 to 12 de is preferred. Each single yarn of the crimped yarn constituting the pile yarn 2 may have a constant denier, but the texture may be improved by mixing single yarns with different deniers within the range of 1 to 50 de. On the other hand, the optimum range of total denier varies depending on the use of the cut pile fabric, but for example, 600 to 6000 de (particularly 900 to 3000 de) is suitable for carpets, and 400 to 900 de for sheet materials and upholstery.

Furthermore, in the present invention, the cross-sectional shape of the filament of the bundled crimped yarn constituting the pile yarn 2 is not limited to the usual circular shape, but also non-circular cross-sectional shapes such as triangular, quadrangular, trilobal, Y-shaped, T-shaped, and cross-shaped. Alternatively, the filament may have one or more hollow portions extending in the longitudinal direction of the filament. Furthermore, in addition to crimping, the bundled crimped yarn may be provided with loops or slack to give it a spun-like texture.

The hand of the bundled crimped yarn can be improved by mixing filaments made of polymers with different melting points and dyeability, such as a combination of polyester (PET or PBT) and polyamide (nylon 6 or nylon 66). , a combination of polypropylene and polyamide, etc., or a combination of different types of polyamides (for example, nylon 6 and nylon 66, nylon 6 and a copolymer thereof) can also be used. Among these polymers, polyamide is most suitable for forming an alternately twisted partially fused crimped yarn because the fiber surface tends to stick to it when exposed to steam. of
Preferably, 50% or more is polyamide filament.

On the other hand, the cut pile fabric proposed earlier looks almost the same as the one in Figure 1 immediately after tufting and cutting, but the pile yarn 2 has a potential torque index of 20 to 300 T/m. It has an inherent and relatively large total crimp ratio. Therefore, when this cut pile fabric is heat-treated in a free state during a dyeing process etc., as shown in Fig. 2, torque is developed in the pile yarn 2 and the actual twist occurs spontaneously, but the single yarn at the tip of the pile yarn 2 Since 3a is twisted or bent by torque, the smoothness of the cut surface is reduced and the cut surface becomes slightly felt-like.

Next, a method for manufacturing the cut pile fabric of the present invention will be explained. That is, the cut pile fabric has (a)
Synthetic multifilament crimped yarn is subjected to false twist fusion processing, so that the constituent single yarns are partially fused to each other, and S twist and Z twist exist alternately at random intervals in the length direction. , and the potential torque index is 60~
(b) The crimped yarn was then subjected to relaxation heat treatment in a restrained state to determine the potential torque index of the crimped yarn.
After 20T/m or more and less than 60T/m, (c) tufting the base fabric using the crimped yarn as pile yarn,
By cutting the looped pile yarn, it can be produced industrially and efficiently.

The crimp performance of the supplied multifilament crimped yarn ("BCF") in the method of the present invention is preferably 3 to 12% in terms of total crimp ratio, and the crimp form is heated fluid injection processing, fluid pressing processing, Non-helical crimp by molding or the like is preferred.

According to the method of the present invention, this crimped yarn is supplied to a false twist heat setting device, a false twist is imparted, the twist is supplied to a heat set device, a false twist is imparted, the twist is heat set, and If the constituent single yarns are partially fused during heat setting and then untwisted and taken off without removing the partially fused parts, the parts where the partially fused pieces have been formed become untwisted and form a filament. As a result, a corresponding twist occurs in the opposite direction, the single yarns are partially fused, and an alternating twist in which S twist and Z twist exist alternately at random intervals in the length direction of the yarn is created. and 60～
It becomes a bundled crimped yarn with a potential torque of 300T/m.

In order to obtain such a bundled crimped yarn, a false twist of 100 to 1000 T/m is applied to the supplied crimped yarn using an air swirl nozzle, and a temperature higher than the partial fusion initiation temperature is applied using saturated or superheated steam. A method of heat setting at a temperature of 1 is suitable, and a pipe heater that directly heats the yarn with steam is suitable as a means for steam heat setting. The degree of partial fusing and alternating twist applied here is such that the cohesion coefficient of the yarn after the false twist fusing process is 5 to 100, particularly 20 to 60,
It is preferable that the potential torque index is 60 T/m or more. This false twist fusing process is advantageously carried out subsequent to the crimping process, and it is also possible to carry out the spinning-drawing-crimping process and the false-twist fusing process successively.

For details on the manufacturing method of such a focused thermoplastic synthetic multifilament crimped yarn, please refer to the Japanese Patent Application No. 53
It is described in the specification of No.-87141 and the specification of Japanese Patent Application No. 54-99854.

In the method of the present invention, such a focused thermoplastic synthetic multifilament crimped yarn is then subjected to a relaxation heat treatment in a constrained state (that is, a state in which the yarn cannot move freely) to alleviate the latent torque in the yarn and Adjust crimp and heat set. This relaxation heat treatment can be carried out by, for example, softly winding a crimped thread onto cheese and heat-treating the cheese with saturated steam at 100 to 130 degrees Celsius in a steam setter, or dyeing the cheese by dissolving a dye in hot water at 80 to 100 degrees Celsius. This is carried out by a method of circulating a liquid and carrying out heat treatment at the same time as dyeing, or by a method of carrying out heat treatment while running the thread between two rollers under constant overfeed.

This heat treatment increases the potential torque index.
20T/m or more, less than 60T/m (preferably 20~
40T/m) and a total crimp rate of 3 to 10% (preferably 4 to 8%), the bundled crimped yarn has virtually no torque and the crimp is stably set at a low level. Therefore, when this is used as a pile yarn and tuffed onto a base fabric and the loop is cut to make a cut pile fabric, there is little twisting or bending at the tip of the pile yarn, and a product with a smooth cut surface can be obtained.

The base fabric and tufting conditions should be selected appropriately depending on the intended use of the cut pile fabric, but in general, when making a cut pile carpet,
Use a 5/64 to 5/32 gauge tufting machine using a thread of about 600 to 6000 de, or 1/16 using a thread of about 400 to 900 de for seat fabrics and upholstery.
It is appropriate to use a tufting machine with a gauge of ~1/20.

If dyeing is carried out simultaneously with the above-mentioned relaxation heat treatment in a restrained state, dyeing with cut pile fabric is not necessary, and finishing such as shearing may be performed subsequent to tufting. In the case of solution-colored yarn, only the heat treatment described above is performed. In this case as well, the pile yarn has been heat-treated to reduce its potential torque, and the crimp is thermally stable.
Even when subjected to heat such as drying, the ends of the pile yarns are less likely to bend or twist, the cut surface is smooth, and shearing is easy. Therefore, in either case, the finally obtained cut pile fabric maintains the pile form as shown in FIG. 1 and is of excellent quality.

In addition, in the method of the present invention, since the potential torque of the pile yarn is substantially small, the effect of rotating the cut pile yarn by the potential torque and adding actual twist to the pile yarn cannot be expected; however, the effect of this twisted yarn is In the false twist fusion process, the partial fusion of the constituent single yarns is further strengthened and the agglomeration coefficient is increased, and alternately twisted S,
Increasing the Z twist and thereby increasing the focusing effect is a sufficient alternative. Therefore, in order to have a sufficient focusing effect, it is preferable to set the cohesion coefficient to 20 or more, but if the cohesion coefficient is too large, the texture will become rough and hard, so the optimum value is 20 to 60.
It is best to adjust it accordingly.

According to the method of the present invention as described above, the multifilament crimped yarn is subjected to false twist fusion processing and heat treatment in a restrained state, so that the yarn cross section becomes approximately circular, and the crimped yarn has a reduced potential torque. Since the yarn is a pile yarn, the manufacturing cost of the pile yarn is low and the tufting property is also good. Furthermore, since there is little substantial torque on the pile yarn, the cut surface is smooth and has excellent shearing properties without twisting or bending the single yarn, and the final cut pile fabric obtained is of high quality, making it suitable for carpets, mats, etc. It has great utility as a sheet material, upholstery material, etc.

Next, the "total crimp rate" and "cohesion coefficient" in the present invention
The method for measuring the "potential torque index" will be explained in detail.

(1) Total crimp rate (TC) Total crimp rate (TC) is the crimp of the yarn.
The crimped yarn is taken out to a length of approximately 1 m from the package cage, the trial length lo is measured after 1 minute under a load of 0.1 g/de, and the crimped yarn is immersed in boiling water for 30 minutes in a free state. After developing crimp and dehydration, the sample was air-dried for one day and night under standard conditions, and then 0.1g/
Measure the length l ₁ after 1 minute with a load of de applied, then measure the test length l ₂ after 1 minute under a load of 2 mg/de after leaving it free for 3 minutes, and use these measurements to determine the total length. The crimp rate (TC) is calculated by the following formula.

TC=l ₁ −l ₂ /l ₁ ×100 (%) (2) Cohesion coefficient (CF) Cohesion coefficient is a value that indicates the convergence of threads,
Both ends of the horizontally placed thread are tension-free, and the thread is divided in half in the axial direction into upper and lower parts.
The upper part was hung on a fixed hook, and a load of 0.2 g/de per total crimped yarn denier was applied to the remaining half of the yarn, and the vertical width W expanded vertically was measured, and the agglomeration coefficient ( CF).

CF=100 (cm)/W (cm) The sample should be 50 cm or more in length and should be randomly collected. This cohesion coefficient (CF)
The larger the value, the higher the convergence.

(3) Potential torque index Remove the crimped yarn from the cheese, collect a length of approximately 30 cm, mark one side of the yarn with oil-based ink, and then soak one end of the yarn in saturated steam (approximately 100℃) for 5 minutes. The thread is hung in a free state, and the number of turns produced by rotation of the thread is counted and converted to the number of turns per meter (T/m), which is used as the potential torque index. The larger this value is, the greater the torque (swirling force) inherent in the yarn is.

Example 1 A multifilament yarn consisting of nylon 6 filaments with a trilobal cross section (irregularity 2.0) was drawn and then processed at a processing speed using a heated fluid injection nozzle.
Crimped at 1000m/min to 1300 denier/136
Following the filament nylon 6 multifilament crimped yarn and no crimping, the crimped yarn is given a false twist of 700 T/m by an air false twisting nozzle,
This false twist was partially fused using superheated steam at a temperature of 200℃ and a relative pressure of 2.0Kg/cm ² using a 50cm long pipe heater (the diameter of the yarn inlet and outlet holes of the pipe heater were 1.1mmφ). , total crimp rate 60%, cohesion coefficient
60, a partially fused crimped yarn bundled into alternately twisted yarns with a potential torque index of 120 T/m was obtained.

This bundled crimped yarn is softly wound with a cheese winder to form a package with a winding density of 0.2 g/cm ³ , and a dye solution of 80 to 100°C is applied to the package for about 1 hour.
Heat treatment was carried out at the same time as dyeing in a time cycle. The crimped yarn after dyeing (heat treatment) has a potential torque index of
Although the cohesion coefficient was reduced to 25 T/m, the cohesion coefficient was 55 and the total crimp rate was 4.5%, and the cohesiveness of the alternately twisted yarn was sufficiently maintained.

Next, this crimped yarn is used as pile yarn to make 10 stitches on a base fabric made of polypropylene slit yarn using a 5/64 inch gauge tufting machine.
Tufting was performed under the conditions of inches and pile height of 15 mm, the loop-shaped pile was cut, and the cut surface was further sheared to obtain a cut pile carpet.

This cut pile carpet had straight piles, and the single threads on the cut surface were not bent or twisted, so shearing was easy and the cut surface was smooth, making it a high-quality carpet.

Example 2 A multifilament crimped yarn (600 denier/136 filaments) consisting of nylon 6 filaments with a trilobal cross section (irregularity of 3.5) was produced by direct spinning, drawing and crimping. The crimping method used was one using heated fluid jet intrusion as disclosed in Japanese Patent Application Laid-Open No. 53-45420, and the processing speed was 3000 m/min. Following the crimping process, this crimped yarn is false-twisted at 1000T/m using an air false-twisting nozzle. Also 0.8mm
φ) Steam temperature 200℃, relative steam pressure
Partially fused heat set in false twist state using superheated steam of 3.5Kg/ ^cm2 , total crimp rate 7.0%, cohesion coefficient 70,
A partially fused multifilament crimped yarn bundled into alternately twisted yarns with a potential torque index of 200 T/m was obtained.

This cohesive multifilament crimped yarn is soft-winded with a cheese winder to a winding density of 0.25 g/
Form a package of cm ³ , the package 80-100
The dye solution was circulated at ℃ for about 1.5 hours, and heat treatment was carried out at the same time as dyeing. After dyeing (heat treatment), the potential torque index of this multifilament crimped yarn decreased to 40T/m, but the cohesion coefficient was 60, the total crimp rate was 5.0%, and the cohesiveness of the alternately twisted yarn was sufficiently maintained. It had been.

Next, this multifilament crimped yarn is used as a pile yarn and tufted onto a base fabric consisting of a woven fabric using a 1/20 inch gauge tufting machine with 25 stitches/inch and a pile height of 7 mm. was cut, and the cut side was further sheared to create a cut pile fabric with a velor feel. When this fabric was used as a fabric for upholstery, very good results were obtained.

[Brief explanation of the drawing]

FIG. 1 is a partially enlarged view schematically showing a cross section of a cut pile fabric of the present invention, and FIG. 2 is a partially enlarged view schematically showing a cross section of a cut pile fabric (after dyeing) previously proposed by the present inventors. It is. 1...Base fabric, 2...Pile thread, 3a, 3b...
Single thread at the tip of the pile thread.

Claims (1)

[Scope of Claims] 1. A cut pile fabric in which tufted pile yarns stand in a row on a base fabric, which has a total crimp rate of 3 to 10%, and has constituent single yarns partially fused to each other and long In the horizontal direction, S twist and Z twist exist alternately at random intervals, and the potential torque index is
A cut pile fabric characterized in that the pile yarn is a bundled thermoplastic synthetic multifilament crimped yarn having a strength of 20 T/m or more and less than 60 T/m. 2. The cut pile fabric according to claim 1, wherein the bundled thermoplastic synthetic multifilament crimped yarn has an average single filament denier of 3 to 15 de and a cohesion coefficient of 5 to 100. 3. The cut pile fabric according to claim 1 or 2, wherein 50% or more of the constituent single yarns of the bundled thermoplastic synthetic multifilament crimped yarn are polyamide filaments. 4 Synthetic multifilament crimped yarn is subjected to false twist fusion processing, so that the constituent single yarns are partially fused to each other, and S twist and Z twist exist alternately at random intervals in the length direction. , and the potential torque index is 60
The crimped yarn is made into a bundled thermoplastic synthetic multifilament crimped yarn with a yield of ~300 T/m, and then the crimped yarn is subjected to a relaxation heat treatment in a restrained state to increase the potential torque of the crimped yarn to 20 T/m.
A method for producing a cut pile fabric, which is characterized in that after the crimped yarn is reduced to less than 60 T/m, the base fabric is tufted using the crimped yarn as a pile yarn, and the looped pile yarn is cut. 5. The method for producing a cut pile fabric according to claim 4, in which the bundled thermoplastic synthetic multifilament crimped yarn is subjected to relaxation heat treatment in a restrained state at the same time as dyeing. 6. The cut pile fabric according to claim 4 or 5, wherein the bundled thermoplastic synthetic multifilament crimped yarn after relaxation heat treatment has a total crimp rate of 3 to 10% and a cohesion coefficient of 5 to 100. manufacturing method.