KR100415731B1 - Process for Manufacturing Poly(trimethylene terephthalate) Bulked Continuous Filament and Carpet - Google Patents

Abstract

The present invention relates to a method for producing polytrimethylene terephthalate (hereinafter referred to as PTT) bulky continuous filament (hereinafter referred to as BCF) and carpet, and more particularly, a release nozzle designed to be suitable for a PTT spinning process in manufacturing BCF. Method of producing a PTT BCF, characterized in that to improve the stability of the spinning process by stretching in two stages at the time of stretching, high-speed spinning of 3000m / min or more to increase the economical efficiency, and to produce a high-strength BCF with high stretching With the manufactured BCF, direct cabling (hereinafter referred to as D / C), heat setting (hereinafter referred to as H / S), tufting, dyeing, backing, It relates to a manufacturing method for the entire process of producing the final carpet through a shearing (Shearing) step.

Description

Process for Manufacturing Poly (trimethylene terephthalate) Bulked Continuous Filament and Carpet}

The present invention relates to a method for producing polytrimethylene terephthalate (poly (trimethylene terephthalate): hereinafter referred to as PTT) bulky continuous filament (hereinafter referred to as BCF) and carpet, and more specifically, disadvantages of PTT material It is possible to manufacture a yarn of higher strength by improving the low strength of phosphorus, and also to improve the spinning workability by improving the stability of the spinning process, and the elastic recovery rate by using the prepared PTT BCF and The present invention relates to a method for producing a carpet having not only antifouling properties and antistatic properties, but also excellent wear resistance and rich volume.

As a synthetic material of BCF used in general carpet production, nylon, polypropylene, polyethylene terephthalate, and the like are typically used. Recently, a process for manufacturing BCF and carpet using PTT material having the advantages of nylon and polyester has been published in research papers and patents. U. S. Patent No. 6,242, 091 describes a process for producing BCF and carpet using PTT in detail at each stage of manufacture. It is a method of manufacturing BCF by one-step drawing. Due to thermal characteristics such as low glass transition temperature and crystallization temperature of PTT material, there is a limit to high drawing. In addition, the BCF prepared by this method has a disadvantage in that the wear resistance of the final product carpet is also weakened due to low strength. The method for producing BCF and carpet using PTT disclosed in US Pat. No. 6,254,961 employs a two-step stretching method as the present invention as an improved method than the BCF manufacturing method according to the one-step stretching method. BCF according to the present invention is capable of high-speed spinning compared to the one-step stretching method, but the appropriate release degree is not selected for PTT material, it is necessary to design a nozzle that can optimize the properties such as spinning workability, bulking properties, strength. In addition, since PTT material exhibits higher bulking properties than nylon due to its material characteristics, the volume of filament is increased, so that partial single yarns occur in the post-processing such as cabling and tufting, and a lot of tearing of the yarn causes serious problems in work stability. In order to improve the workability of the post process, it is necessary to give a certain number of entanglements to focus the filaments. In addition, it is necessary to increase the stability of the spinning operation by giving a rex before final winding. This is because PTT BCF exhibits higher bulking properties than nylon BCF and high specific gravity, which results in an increase in yarn shrinkage and no doping or winding up when proper relex is not involved.

One object of the present invention for solving the problems of the prior art as described above, using a nozzle designed with a mold release suitable for PTT material, adopts a two-step stretching method, 10 to 40 times in a separate focusing device By providing entanglement in units of / m, it is to provide a stable form of PTT BCF that has high-speed radiation and high strength and can improve the workability of the post-process.

Another object of the present invention is direct cabling (Direct Cabling, hereinafter referred to as D / C), heat setting (hereinafter referred to as H / S), and dyeing using PTT BCF prepared by the above method. It is an object of the present invention to provide a method for producing a PTT carpet having excellent quality through the optimization of working conditions in a post process such as backing, shearing, and the like.

That is, one aspect of the invention relates to a process for the preparation of a PTT BCF comprising the following steps:

1) melt spinning a PTT polymer having an intrinsic viscosity of 0.6 to 1.2 and a moisture of 100 ppm or less at a temperature of 245 to 265 ° C. using a nozzle having a release degree of 1.5 to 3.5;

2) cooling to 10-25 ° C. with air at a rate of 0.4-0.6 m / sec in the cooling zone;

3) imparting an emulsion at spin finish using a knit type or water soluble oil;

4) feeding the filament to the first stretching roller at a feed roller at a speed of 650 to 1600 m / min, wherein the first stretching roller is drawn at a speed of 1.005 to 1.2 times the feed roller speed;

5) stretching at a temperature of 130 to 200 ° C. in the second stretching roller and stretching ratio at a speed of 2.4 to 3.8 times that of the first stretching roller;

6) crimping the filament in irregular three dimensions by passing a texturing unit with a texturing nozzle to give bulking property to the filament passing through the second stretching roller and giving 10-50% crimp;

7) cooling the filament passing through the texturing unit to 15-22 ° C. through a cooling drum, and then passing the entanglement machine to give 10-40 times / m entanglement; And

8) Passing at a rate of 0.75 to 0.9 times the speed of the second stretching roller in the rex roller, giving a rex of 10 to 25% and winding at a speed of 1700 to 2800 m / min.

Another aspect of the present invention relates to a method for preparing a PTT BCF carpet by the following steps using the PTT BCF prepared above:

1) to prepare a twisted yarn by two or three twisted yarns in the twisting 180 to 250 / m, S or Z twisting in the cabling twister;

2) heat setting through an autoclave, seesen or superbar;

3) In tufting machines of 1/8, 5/32, or 1/10 gauges, they are planted on PET spunbond or PP films, where the height of the pile is in the range of 4-18 mm for cut piles and 2.5-15 mm for loop piles. And tufting the stitches to have a range of 5 to 15 / inch and a yarn weight of 10 to 90 oz / yd ² ;

4) The tufted carpet is white-dyed without a carrier under normal pressure using a disperse dye, but the OWF (amount of dye input to fabric) is in the range of 0.01 to 3%, and the liquid ratio is in the range of 10: 1 to 25: 1. The dispersing agent is dyed by the addition of 0.25 ~ 1.0g / l dyeing temperature is adjusted to the range of 90 ~ 100 ℃ dyeing;

5) attaching the dyed tuft carpet to the secondary bubble paper such as jute, PP, and backing after latex coating; And

6) Shearing using a spiral knife.

1 is a schematic representation of an apparatus for producing polytrimethylene terephthalate bulky continuous filaments in accordance with the present invention.

<Description of Signs of Major Parts of Drawings>

1. Spinning detention

2. Filament

3. Quenching area

4. Finish appricator

5. Pretension Roller

6. 1st drawing roller

7. 2nd drawing roller

8. Texturing unit

9. Cooling drum

10. Interlacer

11.Relax roller

12. Winder

Hereinafter, the present invention will be described in more detail with reference to the drawings.

1 schematically shows an apparatus for producing a PTT BCF according to the present invention.

First, a PTT polymer having an intrinsic viscosity of 0.6 to 1.2 and a moisture of 100 ppm or less is melt spun at 245 to 265 ° C to pass through the spinneret 1. The nozzle is designed to have a release degree of 1.5 to 3.5. At this time, when using a nozzle having a release degree of less than 1.5, there is no big problem in spinning workability, but it does not have sufficient bulking property, and when using a nozzle having a release degree exceeding 3.5, the elongation of yarn is sharply dropped, and trimming occurs frequently. This becomes difficult.

Thereafter, the cooling zone 3 is cooled with air having a speed of 0.4 to 0.6 m / min. At this time, the cooling temperature is adjusted to 10-25 ℃.

After cooling, go through the spin finish step of oiling. In the first and second stages of the finish applicator (4), oiling using neat type oil or water-soluble oil is carried out. , Improves smoothness.

Thereafter, the filament is supplied to the first drawing roller 6 at a speed of 650 to 1600 m / min in a non-heating state from the supply roller 5, wherein the first drawing roller 6 is supplied at a temperature of 50 to 90 ° C. (5) Stretch at a speed of 1.005 to 1.2 times the speed. Stretching at a rate higher than 90 ° C or faster than 1.2 times results in rapid crystallization and causes trimming. Next, the stretching is carried out in the second stretching roller 7 at a speed of 2.4 to 3.8 times the temperature of 130 to 200 ° C and the stretching speed of the first stretching roller. If the drawing speed is less than 2.4 times, the drawing is not sufficiently stretched, and if the drawing speed is larger than 3.8 times, it is not able to withstand drawing due to the low strength of the PTT material.

The filament passed through the second drawing roller passes through the texturing unit 8 with the texturing nozzle to impart bulking properties. At this time, a pressure of ⁴ to 8 kg / m ² is introduced into the texturing unit at 130 to 220 ° C. Blow the filament into an irregular three-dimensional crimp, and the crimp rate is 10-50%.

The filament passed through the texturing unit is cooled to 15-22 ° C. while passing through the cooling drum 9 and passes through the entanglement device 10. In this part, in order to improve the focusing force of the yarn, a little twist and knot are applied at a pressure of 2.0 to 5.0 kg / m ² , which is given in the range of 10 to 40 times / m. If less than 10 entanglements are given in the entanglement machine, a large amount of tearing occurs during cabling due to the lack of focusing force in general yarns, resulting in a large amount of pliers or pin yarns. The final carpet after finishing work is unfolded and the appearance is not good and durability is also low. In addition, when the entanglement is given more than 40 times, the entangled state remains unchanged even after dyeing and post-processing, thereby damaging the appearance of the carpet.

Thereafter, the rex roller 11 is passed at a speed of 0.75 to 0.9 times the speed of the second stretching roller to give a rex rate of 10 to 25%, and then at a speed of 1700 to 2800 m / min in the final winding machine 12. Wind up. The speed of the winder is usually higher than the speed of the rex roller 11. At this time, if the speed of the Rex roller is less than 0.75 times of the speed of the second stretching roller, the winding is not performed. If the speed of the Rex roller exceeds 0.9 times, the bulking property is reduced and the yarn shrinks significantly.

The method relates to a BCF made of PTT resin only, the step-by-step process is the same when manufacturing the raw yarn according to the use of the carpet, except that the color master batch compared to the base chip input (color master batch) 2-5 in the raw material supply It is also possible to prepare the original yarn by blending spinning by adding a weight%.

PTT BCF prepared by the present invention preferably exhibits the following physical properties:

1) denier; 600-2000;

2) denier per filament (DPF): 10 to 30;

3) strength: 1.8 to 2.5 g / d;

4) elongation: 45-65%;

5) Crimp ratio: 10-50%;

6) non-shrinkage: 3% or less; And

7) Deformation degree: 1.5∼3.5.

BCF prepared as described above is manufactured into a carpet after a few steps as follows.

The BCF prepared in the previous process gives a twist, which is twisted two or three by 180 ~ 250 / m, S or Z twist in a cable twister. At this time, the RPM of the twister is in the range of 4,000 to 4,300.

The twisted yarn is subjected to the H / S process and the apparatus used is Autoclave, Seussen or Superba. In the case of using the super bar, the temperature of the main tunnel is 120 to 160 ° C, the band speed is 5 to 9 m / min, and the density is in the range of 200 to 240 g / m. If the H / S temperature is less than 120 ℃, the bulking property is good, but the heat dissipation is not good enough, so the loosening of the carpet occurs well and the appearance is not good. If the treatment exceeds 160 ℃ bulking property is significantly reduced, there is a disadvantage that does not express a rich volume. Not only the temperature but also the band speed and density affect H / S properties, and if it is out of the above range, it will adversely affect H / S properties as mentioned above. In the H / S process, pre-treatment is also performed before steam setting. This process not only shows the appearance of the carpet more three-dimensionally but also expresses the two-tone effect, enhancing aesthetics and increasing the fixing of the pile. It increases the volume and improves the volume.

Depending on the carpet use, without heat setting, interlocking with 2 or 3 combinations using Intermingle equipment. At this time, the working conditions should be 400 ~ 1000m / min and air pressure 4 ~ 8bar. After this process, the processing company immediately tufts without H / S.

H / S is planted on PET spunbond or PP film in 1/8, 5/32 and 1/10 gauge tufting machines. The height of pile is 4-18mm for cut pile and loop The pile should have a range of 2.5 to 15 mm, the stitch should have a range of 5 to 15 / inch, and the yarn weight used to make carpets should be 10 to 90 oz / yd ² . If the stitch is less than 5 / inch, it does not have sufficient weight and volume as a carpet. If the stitch is more than 15 / inch, the latex is not evenly bonded during the backing process, and thus the drawing strength and peeling strength are significantly reduced.

The tufted carpet is dyed without carrier under normal pressure using a disperse dye, but the OWF (amount of dye input to fabric) is in the range of 0.01 to 3.0%, the liquid ratio is 10: 1 to 25: 1, and the dispersant is 0.25 to Dyeing is added with 1.0g / l and dyeing temperature is in the range of 90 ~ 100 ℃.

Another method is yarn dyeing, in which yarn dyeing is performed simultaneously with heat setting using a continuous yarn dyer, where the color is monochromatic or space dyeing is regularly performed within a range of up to 6 degrees.

Dyeing tufted carpet is applied to secondary foam such as jute and PP foam after latex coating for general home use or commercial use. . The composition of the latex used is about 80% of solids. The detailed composition is composed of 30 to 50% of base latex, 50 to 70% of CaCO ₃ , and other dispersants and thickeners. In order to increase the flame retardant effect, a small amount of Al compound (Al ₂ O ₃ or Al ₂ OH ₃ ) may be added.

In the final process of shearing, the file is evenly cut to improve the appearance of the file after dyeing, using a spiral knife.

PTT BCF carpet prepared as described above preferably exhibits the following physical properties:

1) Carpet type: Cut, Loop, Cut / Loop combi;

2) weight: 30-70 oz / yd ² ;

3) height of cut pile: 4-18mm;

4) roof pile height: 2.5 ~ 15mm;

5) stitch: 5-15 / inch;

6) compression ratio: 30% or more;

7) Compression modulus: 90% or more;

8) drawing strength: more than 2.0kg;

9) Peel strength: 2.0kg or more; And

10) Color fastness: Washing, rubbing, daylight fastness level 4 or more.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the following Examples are for the purpose of explanation and are not intended to limit the present invention.

<BCF Property Evaluation Method>

1) strength, elongation

The test was conducted according to KS K 0412 (Filament's test method for strength and elongation). The test conditions before measurement were 20cm for sample length, 200m / mm tensile speed, 20g for ultra load, and 8 times / 10cm for twist.

2) Crimp rate

A thread is wound on a reel with a circumference of 1m to make a skein according to the following criteria.

The initial tar length (L0) is measured and the yarn is placed in a dry oven at 130 ° C. for 5 minutes. Remove the yarn from the oven and allow to stand for 1 minute. After 50g hanging the weight and measuring the length after 30 seconds. The crimp rate is calculated as follows.

3) Shrinkage rate: Measurement of non-shrinkage rate in KS K 0215

<Workability Evaluation Method>

1) Spinning workability: Number of trimmings for 3 tons of capac.

2) Cabling workability: It shows the tearing property that occurs during work, and is marked as below (A: Good, B: Normal, C: Bad)

3) Tufting workability: It shows the cutting property of pile and the workability is expressed as follows.

(A: Good, B: Normal, C: Poor)

4) Shearing workability: Mark as follows based on the amount of yarn lost during shearing (A: Good, B: Normal, C: Poor)

<Test Method of Carpet Properties>

1) Compression rate / Compression modulus: Tested by method A of KS K 0818

2) Pencil point: Visually observe the degree of loosening of the file and mark it as follows (A: Good, B: Normal, C: Bad)

3) Daylight fastness: Tested according to KS K 0700 standard, judged by gray scale

(Process conditions: 83 ℃, 40hr)

4) Color fastness to washing: Tested by A-1 method of KS K 0430 standard (Processing condition: 40 ℃)

5) Friction fastness: tested by KS K 0650

6) Number of strakes: The number of stray defects generated per one creep during the tufting test

7) Abrasion resistance: Fastness is determined by gray scale after treatment by thickness reduction rate measuring method of KS K 0818 standard.

8) Appearance: The color, gloss, volume, and touch of carpet are expressed as follows (AA: Very good, A: Excellent, B: Normal, C: Poor)

9) Pullout strength: tested by KS K 0818

10) Peeling strength: tested by KS K 0818

Example 1

A PTT polymer with an intrinsic viscosity of 0.92 and a moisture content of 40 ppm was melt-spun at 250 ° C using a nozzle with a release degree 2.1 designed with a Y-section and 68 holes using a Riter spinning machine with a 3 tons of nitrate spinning capa. Cooled to 17 ° C. at a rate of 0.4 m / min in the cooling zone. The feeding roller was supplied to the first drawing roller at a speed of 850 m / min. At this time, the feeding roller was unheated and the first drawing roller at which the first drawing occurred was 50 ° C., at a speed of 935 m / min, which is 1.1 times the feeding roller speed. The drawing was carried out, and the second drawing roller was drawn at 170 ° C. at a speed of 3179 m / min, which is 3.4 times the first drawing roller speed.

The temperature inside the texturing unit was 200 ° C., and the crimping was performed at a pressure of 100 psi. After cooling to 15 ℃ in the cooling drum and 20 times / m at a pressure of 4.0kg / m ^{2 in} the focusing device. In the Rex roller, the rex roller was operated at a speed of 2543 m / min to give 20% of Rex, and at the time of final winding, the speed of the reel was 2600 m / min to produce BCF.

The prepared BCF was combined with 194 / m and Z twist in a cable twister, and then heat-set with a superbar. At this time, the temperature of the main tunnel was 140 ° C, the band speed was 6m / min, and the density was 230g / min. It was set as heat.

The heat-set yarns were planted in PP bubble paper in a 1/10 gauge tufting machine. At this time, the pile was cut pile, the height was 12mm, the stitch was 13 / inch, and the yarn weight was 32oz / sq.yd. Table 1 is a result of evaluating the yarn strength, crimp rate, and tufting workability of BCF manufactured by the above method.

Examples 2 and 3, Comparative Examples 1 to 3

The same procedure as in Example 1 was conducted except that the mold release rate, crimp rate, and spinning rate were changed. Comparative Example 3 is a result of spinning in a conventional manner using a barmag (Barmag) equipment stretching in one step.

division Shape Crimp rate Spinning Speed (Duo2 Speed) burglar Radiation workability (number of trimmings / 3ton) Wear resistance Example 1 2.1 45% 3179m / min 2.3 7 Grade 5 Example 2 1.9 40% 3179m / min 2.3 5 Grade 5 Example 3 2.5 47% 3179m / min 2.2 8 4-5 class Comparative Example 1 1.3 22% 3179m / min 2.2 15 Grade 4 Comparative Example 2 4.0 Not measurable Not measurable Not measurable Not measurable Not measurable Comparative Example 3 2.1 52% 2400 m / min 2.1 8 Grade 4

Note) Depth of Drawing: Ratio of outer diameter to the diameter adjacent to the inside of Y-shaped yarn cross section.

As shown in Examples 1, 2, and 3, the BCF prepared through the nozzle designed within the range of 1.5 to 3.5 has high strength and excellent spinning workability. In addition, it showed excellent fastness in abrasion resistance test after tufting. Compared to the BCF radiated from the barmag machine adopting the one-stage stretching of Comparative Example 3, the crimp rate is slightly decreased due to the high stretching, but high-speed spinning is possible, which has the advantage of high productivity.

As in Comparative Example 1, under the low release degree, the spinning speed and strength similar to those of the Example can be maintained, but the crimp rate and the wear resistance are somewhat decreased. It didn't work. This is because under high mold release, it cannot withstand high elongation due to PTT material properties.

The crimp rate in Comparative Example 3 prepared by the one-step drawing method is superior to the two-step drawing and other physical properties are also equivalent, but has a disadvantage in that the spinning speed is low in terms of productivity and the strength is also relatively low in wear resistance.

Examples 4-5 and Comparative Examples 3-4

In this example, a nozzle having a degree of release of 2.1 was used, and experiments were performed by varying the number of entanglements in a separate entanglement apparatus. Other conditions were carried out similarly to Example 1, and tufted.

The tufted carpet was dyed without carrier using normal dye DIANIX combination under normal pressure, OWF was 0.01%, liquid ratio was 20: 1, dispersant was added 0.5g / l , dyeing temperature was 98 ℃. . The dyed tufted carpet was attached to the secondary bubble jute after latex coating by adding 35% base latex, 60% CaCO ₃ , and other dispersants and thickeners. Afterwards, the shearing step was performed with a spiral knife in the shearing step.

Table 2 is a result of evaluating the workability and quality of the post-process by the BCF company manufactured according to the above method.

division Denomination Cabling Workability Tufting workability Number of strikes Pencil point Example 4 20 times / min A A 10 A Example 5 25 times / min A A 15 A Comparative Example 3 Uninterested C C Not measurable Not measurable Comparative Example 4 50 times / min A A 60 B

In Examples 4 and 5, the number of interlocks was adjusted to 20 and 25 cycles / m, respectively, and the tufting workability and the pen point were excellent, and the number of strikes was also less than 20. In Comparative Example 3, there was no entanglement, and the workability was poor due to excessive tearing during the cabling, and normal cutting was not performed during the tufting work due to deterioration of physical properties such as part trimming of the yarn. In Comparative Example 4, it was difficult to develop into a normal product due to the occurrence of a large number of strikes and a disproportionate at the time of dyeing due to entanglement at 50 times / m.

Examples 6-8 and Comparative Examples 5-8

In this embodiment, the feed roller speed was the same as 850m / min, and the first and second stage draw ratio and the reeling roller before winding by varying the speed to evaluate the properties according to the draw ratio and the Rex rate, other manufacturing The conditions were the same as in Example 4.

Table 3 shows the results of evaluating the physical properties and workability of the BCF prepared according to the above method.

division Stage 1 extension fee Stage 2 extension fee Rex rate Spinning Speed (Duo2 Speed) burglar Cabling Workability Remarks Example 6 1.1 3.4 15% 3179m / min 2.3 A Example 7 1.1 3.2 15% 2992m / min 2.2 A Example 8 1.1 3.4 10% 3179m / min 2.3 B Comparative Example 5 1.1 3.2 8% 2992m / min 2.2 B Doping not allowed Comparative Example 6 1.1 3.2 30% 2992m / min 2.2 C Winding Comparative Example 7 1.0 3.7 20% 3154m / min Not measurable Not measurable No thread Comparative Example 8 2.0 1.85 20% 3145m / min Not measurable Not measurable No thread

Rex rate

As shown in the examples, when the wire is stretched through the first and second steps and wound with the appropriate rex, the high-strength yarn was obtained while high-speed spinning was possible. As can be seen in Examples 6 and 8, when the draw ratio is high as 3.4, the strength may be slightly increased. As in Example 8, when the Rex rate is 10%, the workability is somewhat inferior, such as unwinding of the yarn during tearing and tearing yarns. Comparative Examples 5 and 6 were different in rex rate under the same drawing conditions as in Example 7, there was a problem that the doping in the auto-doping system due to the shrinkage of the yarn when the rex rate is 8%, 30% Occurred a lot and was not wound up.

Comparative Examples 7, 8 were tested with the same ratio of Rex, with the first and second draw ratios exceeding the appropriate ranges. In Comparative Example 7, the samples were continuously trimmed when overdrawn in step 2 without drawing in step 1. Due to this occurrence, the operation was not possible, and in Comparative Example 8, when excessively giving one-step stretching, trimming continued due to rapid crystallization, and thus winding could not be performed.

Example 9 and Comparative Example 9

Example 9 of the present experiment was the same as that of Example 4 except that 3% of the color master batch was added to the amount of PTT base chip input to supply raw materials in the experiment of blending and spinning the color master batch. It was carried out. However, because it is an original yarn, it did not go through a separate dyeing process.

Table 4 shows the results of comparing the original PTT carpet prepared according to the above-mentioned method with the general posterior PTT carpet.

division Compression rate Compressive modulus Color fastness (laundry, daylight, friction) Number of strikes Example 9 38% 92% 5th grade each 3 Comparative Example 9 43% 94% Level 4, Level 4, Level 5 10

The original PTT carpets were superior to the general carpets in terms of color fastness and strike resistance. On the contrary, since it does not undergo dyeing, there is no growth of latent bulk expressed in the dyeing process, and thus, it may be seen that it is somewhat disadvantageous in terms of compressibility or compressive modulus.

Example 10 and Comparative Examples 10-15

In Example 10, the yarns of Example 1 were heat-set with the following conditions in order to see the change of physical properties according to the process conditions in the heat setting step, and the tufting, dyeing, backing, and shearing processes after carpet production Was carried out. Table 5 shows the heat setting process conditions and Table 6 shows the analysis results.

Comparative Examples 10 to 11 selected working conditions to receive less heat history than Examples, and Comparative Examples 12 to 14 selected working conditions to receive more heat history than the Examples.

Operation is impossible on conditions exceeding the conditions described in the comparative example.

division Main tunnel temperature Band speed Yarn Density Above Band Example 10 138 ℃ 6m / 70sec 240g / m Comparative Example 10 138 ℃ 10m / 70sec 240g / m Comparative Example 11 138 ℃ 6m / 70sec 300g / m Comparative Example 12 170 ℃ 6m / 70sec 240g / m Comparative Example 13 138 ℃ 4m / 70sec 240g / m Comparative Example 14 138 ℃ 6m / 70sec 180 g / m

division Exterior Pensil points Friction fastness Example 10 AA A Grade 5 Comparative Example 10 AA B Grade 4 Comparative Example 11 AA B Grade 5 Comparative Example 12 B A Grade 5 Comparative Example 13 A A Grade 5 Comparative Example 14 A A Grade 5

Under the heat treatment conditions as in Example 10, it shows the best physical properties in appearance, unwinding, fastness.

When the band speed is increased as in Comparative Example 10, or the yarn density is increased in the band as in Comparative Example 11, and the thermal history is less than that in the Example, the heat stability is lowered, and thus the ability to endure the end carpet or the friction of the final carpet is weakened. As in Comparative Examples 12 to 14, if the main tunnel temperature is increased, the band speed is slowed, or the yarn density on the band is reduced to receive a lot of heat history, the color fastness is improved, but the bulking property of the carpet is poor, and the appearance of volume and touch is reduced. Has the disadvantage of falling.

Experimental results show that temperature is the most important factor in the process, but the selection of band speed and density is also an important factor for carpet properties.

The present invention can produce a high-productivity BCF through high-speed spinning under a more stable spinning operation even in the production of BCF with PTT material, and can improve the low strength, which is a disadvantage of PTT material, to produce a yarn of higher strength. This can improve the wear resistance of the carpet. In addition, in manufacturing the carpet with the BCF prepared by the present invention, by more specific process conditions for each step compared to the conventional method, it is possible to make a carpet excellent in stability, quality and functionality.

Claims (9)

Process for preparing PTT BCF comprising the following steps: 1) melt spinning a PTT polymer having an intrinsic viscosity of 0.6 to 1.2 and a moisture of 100 ppm or less at a temperature of 245 to 265 ° C. using a nozzle having a release degree of 1.5 to 3.5; 2) cooling to 10-25 ° C. with air at a rate of 0.4-0.6 m / sec in the cooling zone; 3) imparting an emulsion at spin finish using a knit type or water soluble oil; 4) feeding the filament to the first stretching roller at a feed roller at a speed of 650 to 1600 m / min, wherein the first stretching roller is drawn at a speed of 1.005 to 1.2 times the feed roller speed; 5) stretching at a temperature of 130 to 200 ° C. in the second stretching roller and stretching ratio at a speed of 2.4 to 3.8 times that of the first stretching roller; 6) crimping the filament in irregular three dimensions by passing a texturing unit with a texturing nozzle to give bulking property to the filament passing through the second stretching roller and giving 10-50% crimp; 7) cooling the filament passing through the texturing unit to 15-22 ° C. through a cooling drum, and then passing the entanglement machine to give 10-40 times / m entanglement; And 8) Passing at a speed of 0.75 to 0.9 times the speed of the second stretching roller in the rex roller to give a rex of 10 to 25%, and winding at a speed of 1700 to 2800 m / min. The method for producing PTT BCF according to claim 1, wherein 2 to 5 wt% of a color masterbatch is spun on the polytrimethylene terephthalate polymer during melt spinning of the PTT BCF yarn. Method for producing a PTT BCF carpet using the PTT BCF prepared by claim 1 through the following steps: 1) to prepare a twisted yarn by two or three twisted yarns in the twisting 180 to 250 / m, S or Z twisting in the cabling twister; 2) heat setting through an autoclave, seesen or superbar; 3) In a tufting device of 1/8, 5/32 or 1/10 gauge, it is planted on PET or PP bubble paper, and the height of pile is within the range of 4-18mm for cut pile and 2.5-15mm for loop pile. And the stitching has a range of 5 to 15 / inch and tufting the yarn weight to have 10 to 90 oz / yd ² ; 4) The tufted carpet is white-dyed without a carrier under normal pressure using a disperse dye, but the OWF (amount of dye input to fabric) is in the range of 0.01 to 3%, and the liquid ratio is in the range of 10: 1 to 25: 1. The dispersing agent is dyed by the addition of 0.25 ~ 1.0g / l dyeing temperature is adjusted to the range of 90 ~ 100 ℃ dyeing; 5) backing the dyed tuft carpet by latex coating to a secondary bubble paper; And 6) Shearing using a spiral knife. The method of claim 3, wherein the super bar is used for heat setting, but the temperature of the main tunnel is 120 to 160 ° C, the band speed is 5 to 9 m / min, and the density is in the range of 200 to 240 g / m. Method for producing a PTT BCF carpet, characterized in that. The method of claim 3, wherein the yarn used for tufting is two or three by an intermingle device without undergoing a heat setting process, wherein the speed is 400 to 1000 m / min, the air pressure is adjusted to 4 to 8 bar Method for producing a PTT BCF carpet, characterized in that. The method for producing PTT BCF carpets according to claim 3, wherein the PTT BCF carpet is prepared by pre-friing before the heat setting step. 4. The method according to claim 3, wherein the method uses a continuous yarn dyeing machine and heats yarns simultaneously with heat setting, wherein the color is dyed with regular space dyeing within a monochromatic or 6 degree color range. Method for producing carpet. PTT BCF prepared by the method of claim 1 having the following physical properties: 1) denier; 600-2000; 2) denier per filament (DPF): 10 to 30; 3) strength: 1.8 to 2.5 g / d; 4) elongation: 45-65%; 5) Crimp ratio: 10-50%; 6) non-shrinkage: 3% or less; And 7) Deformation degree: 1.5∼3.5. PTT BCF carpet prepared by the method of claim 3 having the following physical properties: 1) Carpet type: Cut, Loop, Cut / Loop combi; 2) weight: 30-70 oz / yd ² ; 3) height of cut pile: 4-18mm; 4) roof pile height: 2.5 ~ 15mm; 5) stitch: 5-15 / inch; 6) compression ratio: 30% or more; 7) Compression modulus: 90% or more; 8) drawing strength: more than 2.0kg; 9) Peel strength: 2.0kg or more; And 10) Color fastness: Washing, rubbing, daylight fastness level 4 or more.