JP3885610B2 - Crimp yarns and carpets for carpets - Google Patents

Description

【００９９】
比較例１においては通常の単一断面で構成された捲縮糸であるため、タテ筋、カバーリング性が特に不良であった。また比較例２では異なる２群が混在する構成であるためタテ筋、カバーリング性が不良であった。また比較例３では３群間の変形度、単糸繊度の差が不十分でありタテ筋、カバーリング性が不良であった。また比較例４では４群間の変形度、単糸繊度の差が不十分でありタテ筋、カバーリング性が不良であった。
【０１００】
【発明の効果】
本発明のカーペット用捲縮糸は、特に単色のカットパイルカーペットによく見られるタテ筋の発生を抑えることができ、かつカバーリング性が良好なカーペットを与えることができる。また、本発明のカーペットは、上記カーペット用捲縮糸の特性をそのまま生かしたものであり、特にオプションカーペット、ロールカーペット、ラインカーペットとして好適である。
【図面の簡単な説明】
【図１】本発明の捲縮糸を構成するＹ型断面マルチフィラメントの一例を示す断面図である。
【図２】Ｙ型断面単糸の変形度の測定に用いる内接円、外接円を例示した模式図である。
【符号の説明】
１：内接円
２：外接円[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a crimped yarn for carpet and a carpet using the crimped yarn. More particularly, the present invention relates to a crimped yarn for carpet that can suppress the occurrence of vertical stripes often seen in a single-color cut-pile carpet and has a good covering property, and a carpet using the crimped yarn. .
[0002]
[Prior art]
The main purpose of use of carpets is to provide functions and atmospheres that are well adapted to interior applications, and various characteristics such as texture and volume are required in addition to colors and patterns. Of these, carpets such as option carpets, roll carpets, and line carpets have been required to have excellent cushioning properties and high-class feel, as well as excellent interior space rendering properties, in particular, a uniform and calm atmosphere. For this reason, these carpets are often made up of timeless monochromatic colors.
[0003]
On the other hand, a carpet is manufactured by tufting hundreds to nearly 2,000 crimped yarns substantially parallel to the base fabric. Therefore, if there is a difference in the characteristics of the adjacent crimped yarns on the carpet and a difference in color occurs, it will be visually recognized as a vertical line. This warp streak is not preferable because it lowers the quality of the carpet. In particular, in the case of a cut pile using a single color, there is a drawback that the warp streak tends to occur due to a slight difference in the crimp characteristics of the pile used.
[0004]
As the cause of the generation of this vertical muscle, there are mainly two types of factors, ie, morphological differences and dyeing differences. The vertical streak caused by the morphological difference is a phenomenon in which the height of the pile is different on the surface of the carpet when the level of crimp of the crimped yarn constituting the pile differs depending on the pile constituting the carpet, and it appears as a streak. . On the other hand, warp streaks due to dyeing differences differ in the fiber structure of the crimped yarn constituting the pile depending on the pile, so the degree of dye adsorption differs when the carpet is dyed, and this is recognized as a streak. is there. Of course, both the above-described difference in form and dyeing are often combined to form a vertical line.
[0005]
Conventionally, various proposals have been made to reduce the vertical length of carpets. For example, in a manufacturer who performs tufting, in order to reduce warp, the same quality as much as possible can be obtained by using, for example, a crimped yarn produced on the same machine at almost the same time as a crimped yarn used for one carpet. In other words, complicated management has been carried out, such as using a crimped yarn of only the above, or using only a crimped yarn having a degree of deformation and an L value within a certain range. However, even if such measures are taken, the occurrence of vertical muscle is not completely eliminated.
[0006]
Moreover, in order to reduce the difference in the characteristics of the inner and outer layers of the crimped cheese that has been wound up as a means for reducing warp, the winding tension is lowered, or, for example, described in JP-B-57-2627 As described above, there has been proposed a device for adding water to the yarn immediately before winding to stabilize the yarn, but none of them has solved vertical warp. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0007]
Japanese Examined Patent Publication No. 58-51048 proposes an attempt to obtain a uniform crimped yarn by defining a heat shrinkage rate and a preheating temperature when crimping is applied in a crimp nozzle. In the method, there is a limit to uniformity, and a crimped yarn that can withstand subsequent process variations cannot be obtained, and the vertical warp of the carpet has not been reduced. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0008]
Once the crimped yarn is formed, some abnormal tension is applied to a part of the crimped yarn in the process of rewinding or dyeing, and even when the crimp is partially stretched, warp streaks due to morphological differences occur. It is thought that. For this reason, there is an attempt to reduce the warp by increasing the crimp level of the crimped yarn to make the crimped yarn resistant to process variations in the processing process. However, this method alone cannot completely absorb the effects of process fluctuations, so the obtained effect of reducing the warp streak is slight, and the average crimp level of the crimped yarn is high. The texture was hard and felt like a felt-like. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0009]
Japanese Examined Patent Publication No. 63-16487 discloses a method for obtaining a stable low crimped yarn by steam heat setting of the crimped yarn. However, with this method, it is not possible to set to withstand fluctuations in the winding tension after setting, and it is difficult to completely solve the warp, and the crimped yarn is passed through the steam pipe. In passing, the process passability was poor, and a stable crimped yarn could not be obtained. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0010]
Various improvement proposals have been made as described above, but these proposals all try to reduce the warp by creating a more uniform crimped yarn. There was a limit to the improvement effect.
[0011]
Further, in Japanese Patent Publication No. 8-13287 and Japanese Patent No. 2853873, by combining multifilaments having different degrees of deformation and fineness, crimped yarns and carpets for carpets having a soft surface touch and a firm waist are provided. A method of obtaining has been proposed. However, in this proposal, the structure of each multifilament to be mixed is not appropriate, and although the texture of the resulting carpet is changed, the effect of reducing the vertical stripes is not sufficient. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0012]
In addition to using only one pile color, two similar colored piles are arranged side by side to create a pile or twisted saxony to reduce the vertical streak. All of the methods can be used only within a limited range in terms of required quality and standards.
[0013]
On the other hand, Japanese Patent Laid-Open No. 63-120134 proposes a fabric using three or more kinds of cross-sectional yarns for polyester-based multifilaments, but this proposal brings the texture of fibers close to silk in clothing applications. Therefore, there is no technical idea of applying this fiber to a crimped yarn for carpet to reduce the warp.
[0014]
Japanese Examined Patent Publication No. 1-23577 proposes an example in which a crimped yarn using polymers having different shrinkage characteristics is mixed to make a carpet showing the bulkiness and texture of spanlike.
[0015]
In this carpet, since the tip of the pile faces in various directions, an effect is recognized to some extent in terms of reducing the vertical muscles, but the manufacturing process is complicated due to the use of two types of polymers. Thus, since a copolymer polymer having a high copolymer component is used as one kind of polymer, there is a problem that the durability of the crimped yarn is inferior. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0016]
Furthermore, crimped yarns used for tile carpets are made by mixing two or more types of crimped yarns having different dyeing properties by entanglement to create a carpet pattern. Here, there are also proposed ones in which the single yarn cross-section is different for each crimped yarn exhibiting mixed dyeing. However, in this example, the polymer used is different, and the purpose is to create a pattern, and it does not reduce the vertical muscle. In addition, although high entanglement is applied to express the pattern, there is no problem as a loop, but the converging part remains in the cut pile, and the carpet has poor volume feeling. In addition, in Japanese Patent Publication No. 1-23577, there is no idea of reducing warp by mixing crimped yarns having different degrees of deformation and single yarn fineness in crimped yarns made of the same polymer. It was. In addition, there is no mention of improving the covering property when the carpet is used, and it is not recognized as a problem.
[0017]
[Problems to be solved by the invention]
As described above, a crimped yarn for carpet and a carpet capable of suppressing the occurrence of warp streak often observed particularly in a single-color cut pile carpet have not been obtained. At the same time, a carpet crimped yarn and a carpet for improving carpet covering have not been obtained.
[0018]
The present invention has been achieved as a result of studying the solution of the problems in the prior art described above as an issue. Accordingly, an object of the present invention is to provide a crimped yarn for a carpet and a carpet that can suppress the occurrence of warp lines often seen particularly in a single-color cut-pile carpet and have good covering properties.
[0019]
[Means for Solving the Problems]
In order to solve the above problems, the crimped yarn for carpet of the present invention mainly has the following configuration.
That is, it is a crimped yarn in which at least one of the degree of deformation and the single yarn fineness is mixed with three or more Y-shaped cross-sectional multifilaments that are different between any two groups, and the polymer constituting the crimped yarn is independent of the group It is the crimped yarn for carpet characterized by being the same.
[0020]
The carpet of the present invention is characterized in that such a crimped yarn for carpet is used for a pile constituting the carpet.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
The inventors of the present invention have found that two groups of Y-shaped multi-filaments having different degrees of deformation are mixed so that carpet warp and carpet can be suppressed, and two groups having different single yarn fineness. First, a crimped yarn for carpet and a carpet capable of suppressing the vertical warp of the carpet by mixing the Y-shaped multifilaments of the present invention have been proposed.
[0022]
These proposals are not the idea of reducing the warp by using a more uniform crimped yarn than the conventional one, but even if there is a factor of the warp in the crimped yarn with some variation, it is visually recognized as a warp. This is based on the principle that it is difficult to perform.
[0023]
After that, as a result of further studies by the present inventors, crimps in which three or more groups of Y-shaped cross-sectional multifilaments configured such that at least one of the degree of deformation and the single yarn fineness is different between any two groups are mixed. In the yarn, it has been found that the effect of reducing the warp is further improved than the previous proposal, and in addition, the covering property of the carpet is improved.
[0024]
The reason why the vertical muscle reduction effect is further improved by the present invention than the previous proposal is as follows. The previous proposal is a crimped yarn in which two groups of Y-shaped multifilaments having the same single yarn fineness and different degrees of deformation are mixed, or two groups of Y-shaped cross-sectional multifilaments having the same degree of deformation and different single yarn finenesses. It was a mixed crimped yarn.
[0025]
That is, both of them were crimped yarns in which two groups of Y-shaped cross-section multifilaments differing in only one of the single yarn fineness and the degree of deformation were mixed. On the other hand, in the present invention, since the number of mixed Y-shaped cross-sectional multifilament groups is increased to 3 or more, the variation effect is large, and the vertical stripe reduction effect is further improved.
[0026]
In addition, the crimped yarn for carpet according to the present invention has a very large variation effect, which is a reason for the effect of reducing warp, and the crimped form of single yarn varies from group to group. Due to the difference in the crimp form between the groups, the bulge of the crimped yarn is improved. Therefore, the covering property is improved as compared with the conventional crimped yarn when the carpet is used.
[0027]
In the present invention, it is necessary to be a crimped yarn for carpet in which at least one of the degree of deformation and the single yarn fineness is mixed with three or more Y-shaped cross-sectional multifilaments different between any two groups.
[0028]
Here, the “group” indicates a single yarn group in which a plurality of single yarns having the same degree of deformation and single yarn fineness are assembled. “Mixed” indicates that they are gathered together. In other words, “crimped yarn in which three or more groups of Y-shaped cross-sectional multifilaments are mixed” means that there are three groups of single yarn groups each composed of Y-shaped cross-sectional single yarns having a specific degree of deformation and single yarn fineness. The three multifilament groups are gathered into a single crimped yarn.
[0029]
Here, the single yarns between different groups may be mixed, and the crimped yarns may be combined into one in a state where the respective groups are substantially separated. However, a crimped yarn in which single yarns between different groups are mixed to some extent and mixed is preferable.
[0030]
The degree of deformation is different between the two groups when the degree of deformation of one group to be compared is Mi and the degree of deformation of the other group is Mj.
Mi / Mj ≦ 1 / 1.2 or 1.2 ≦ Mi / Mj
Means satisfying the relationship.
[0031]
Similarly, when the single yarn fineness is different between the two groups, the single yarn fineness of one group to be compared is Ti, and the single yarn fineness of the other group is Tj.
Ti / Tj ≦ 1 / 1.2 or 1.2 ≦ Ti / Tj
Means satisfying the relationship.
[0032]
When it is not a crimped yarn for carpets in which at least one of the degree of deformation and the fineness of the single yarn is mixed with three or more Y-shaped cross-section multifilaments that differ between any two groups, the variation effect is small and the warp streaking effect is reduced. Both the improvement of the covering property and the covering property will be insufficient.
[0033]
In the present invention, it is necessary for each group that the single yarn has a Y-shaped cross section. Here, the Y-shaped cross section is not particularly limited as long as it is a cross section having convex portions in three directions, but has a convex portion in three directions in a cross section perpendicular to the longitudinal direction of the single yarn as shown in FIG. And it is the cross section where the three convex parts are connected by the smooth recessed part. For example, it is described in FIG. 1 of Japanese Patent Publication No. 2-8044. Three protrusions give a sense of volume and bulkiness as a pile, creating excellent cushioning. Here, as shown in FIG. 2, when the diameter of the circumscribed circle of the Y-shaped cross section is g and the diameter of the inscribed circle is h, the degree of deformation M is defined as M = g / h.
[0034]
As described above, the crimped yarn for carpet according to the present invention may require a certain degree of deformation difference. The range of the degree of deformation is not particularly limited, but all groups are preferably in the range of 1.5 to 5.0. By setting the degree of deformation within this range, it is possible to stably produce crimped yarns with better volume feeling and durability.
[0035]
Similarly, the crimped yarn for carpet of the present invention may require a certain single yarn fineness difference. The range of the single yarn fineness is not particularly limited, but it is preferable that all the groups are in the range of 5 to 30 dtex. By setting the single yarn fineness within this range, it is possible to stably produce a crimped yarn having better durability and resilience.
[0036]
In the crimped yarn for carpet of the present invention, the polymers constituting the crimped yarn need to be the same regardless of the group. Here, the same polymer means that the polymers used in the spinning stage are the same. When the polymer species is changed for each group, the manufacturing process becomes complicated and the gloss and dyeability itself are different, so that the effect of reducing the vertical stripes due to the variation effect of the present invention is reduced.
[0037]
In the present invention, it is preferable that the degree of deformation of all groups is the same. Here, the degree of deformation of all groups is the same, when the degree of deformation of one group to be compared is Mi and the degree of deformation of the other group is Mj,
1 / 1.15 ≦ Mi / Mj ≦ 1.15
This means that the above relationship is satisfied in any combination of two groups. More preferably,
1 / 1.1 ≦ Mi / Mj ≦ 1.1
It is preferable to satisfy the relationship in any combination of two groups. The crimped yarn for carpet having such a configuration has a characteristic that the covering property is particularly excellent.
[0038]
In the present invention, it is also preferable that the single yarn fineness of all groups is the same. Here, when the single yarn fineness of all groups is the same, when the single yarn fineness of one group to be compared is Ti and the single yarn fineness of the other group is Tj,
1 / 1.15 ≦ Ti / Tj ≦ 1.15
This means that the above relationship is satisfied in any combination of two groups. More preferably,
1 / 1.1 ≦ Ti / Tj ≦ 1.1
It is preferable to satisfy the relationship in any combination of two groups. The crimped yarn for carpet having such a configuration has a feature that the effect of reducing warp is particularly excellent.
[0039]
In the present invention, it is also preferable that the mixed Y-shaped cross-sectional multifilaments are 3 or 4 groups. Such a configuration is preferable because the crimped yarn can be produced relatively easily.
[0040]
In the present invention, it is a crimped yarn in which four different groups of Y-shaped cross-sectional multifilaments are mixed, the first group of deformation M1, single yarn fineness T1, the second group of deformation M2, single yarn fineness T2. It is also preferred that the third group of deformation M3, single yarn fineness T3, the fourth group of deformation M4, single yarn fineness T4 is a crimped yarn in the range of the following formulas (1) to (6).
[0041]
(1) 1 / 1.15 ≦ M2 / M1 ≦ 1.15
(2) 1 / 1.15 ≦ M4 / M3 ≦ 1.15
(3) 1 / 1.15 ≦ T3 / T1 ≦ 1.15
(4) 1 / 1.15 ≦ T4 / T2 ≦ 1.15
(5) 1.2 ≦ Mk / Ml
(Established by any combination of k = 1, 2, 1 = 3,4)
(6) 1.2 ≦ Tk / Tl
(Established by any combination of k = 1, 3, l = 2, 4).
[0042]
Here, Expression (1) indicates that the deformation degrees of the first group and the second group are substantially the same. Similarly, Expression (2) indicates that the third group and the fourth group have substantially the same degree of deformation. Formula (3) shows that the single yarn fineness of the first group and the third group is substantially the same. Similarly, formula (4) shows that the single yarn fineness of the second group and the fourth group is substantially the same. Equation (5) indicates that the degree of deformation of the first and second groups is 1.2 times or more of the degree of deformation of the third and fourth groups. Similarly, formula (6) indicates that the single yarn fineness of the first and third groups is 1.2 times or more of the single yarn fineness of the second and fourth groups.
[0043]
In other words, the expressions (1) to (6) are crimped yarns in which a group of two types of deformation (degree of deformation: large, small) × two types of single yarn fineness (single yarn fineness: large, small) = four types are mixed. It shows that there is. More specifically, the first group (deformation degree: large, single yarn fineness: large), the second group (deformation degree: large, single yarn fineness: small), and the third group (deformation degree: small, single yarn fineness: large). ) And 4th group (degree of deformation: small, single yarn fineness: small).
[0044]
The crimped yarn having such a configuration is preferable because it has two types of deformation and the same number of single yarn finenesses, and thus has a good balance between the effect of reducing warp and the effect of improving covering properties.
[0045]
In the crimped yarn for carpet of the present invention, it is preferable that the fineness of each multifilament group is substantially the same. When the fineness of one group to be compared is Di and the fineness of the other group is Dj,
1 / 1.15 ≦ Di / Dj ≦ 1.15
This means that the above relationship is satisfied in any combination of two groups. More preferably,
1 / 1.1 ≦ Di / Dj ≦ 1.1
It is preferable to satisfy the relationship in any combination of two groups. In the case of such a configuration, the characteristics between different groups are averaged and appear on the carpet surface, and the effect of reducing the vertical stripes and the effect of improving the covering property are more effectively exhibited.
[0046]
In the crimped yarn for carpet of the present invention, the total fineness is preferably 600 to 2200 dtex, and more preferably 1000 to 2000 dtex.
[0047]
If the total fineness is lower than 600 dtex, it will take more than necessary to maintain the basis weight of the carpet, and it will be necessary to raise the gauge and stitches. Etc. occur frequently, and it tends to be lacking in process stability. On the other hand, if it exceeds 2200 dtex, it is necessary to lower gauges and stitches for roll carpets and line carpets, and it is too thick to make tufting difficult, and it is necessary to devise tuft conditions.
[0048]
In the crimped yarn for carpet of the present invention, the crimp elongation after the boiling water treatment is preferably 5 to 28%, and more preferably 10 to 24%.
[0049]
If the crimp elongation after treatment with boiling water is less than 5%, the expression of crimp is insufficient, and the carpet tends to have poor volume. On the other hand, if the crimp elongation after boiling water treatment exceeds 28%, the expression of crimp is large when the carpet is finished through dyeing / backing. It tends to become a felt-like carpet.
[0050]
Even when the crimp elongation after the boiling water treatment exceeds 28%, as described in, for example, Japanese Patent Publication No. 60-47949, low tension while unwinding the crimped raw yarn in a separate process A crimped yarn preferable for the present invention can be obtained by performing a heat treatment under the heat treatment in the state of cheese or lowering the crimp elongation after the boiling water treatment to 28% or less.
[0051]
The heat treatment under such tension may be performed in the state of cheese or bobbin, or may be set while unwinding the crimped yarn once wound. The tension applied here is for moderately reducing the crimp while leaving fine fine crimps, and usually depends on the crimp level and the cross-sectional structure of the crimp yarn, but is usually 0.0079-0. A tension of 119 cN / dtex (0.009 to 0.135 g / dtex) is selected. The heat treatment temperature is preferably 80 to 130 ° C. As the heat treatment, a treatment in a bath at a corresponding temperature, a treatment in an atmosphere of dry heat or steam, or a method of passing these atmospheres is adopted.
[0052]
Furthermore, you may give a twist set process as another means for making the crimp extension rate after a boiling water process into the preferable range of this invention.
[0053]
The crimped yarn for carpet of the present invention preferably has an entanglement number of 20 pieces / m or less. When the number of entanglements exceeds 20 / m, the volume feeling, that is, the bulkiness when the carpet is made strong is easily lost. In particular, in the case of cut piles, entanglement often remains and the texture is hard and the carpet tends to be transparent.
[0054]
The polymer constituting the carpet of the present invention can be used without particular limitation as long as it can be processed into a yarn and can be crimped. Specific examples of the polymer that can be used include polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate, polyamides such as polycoupleramide and polyhexamethylene adipamide, and the like. From the viewpoint of impact resilience and durability, polyamide is preferred. Of these, polycapramide is more advantageous in terms of versatility and color developability. Polyhexamethylene adipamide is more advantageous in terms of impact resilience and durability.
[0055]
In addition, as a polymer, the copolymer containing a copolymerization component may be sufficient as long as the effect of this invention is not impaired. Furthermore, in order to improve the spinning performance and the quality of the final product, it is possible to add a copolymer component or particles such as a matting agent. In the case of polyamide, specific copolymerization components include ε-caproamide, tetramethylene adipamide, hexamethylene sebacamide, hexamethylene isophthalamide, tetramethylene terephthalamide, and xylylene phthalamide. . As the matting agent, titanium oxide is preferably used. In order to improve the contamination, a sulfonated copolymer polyamide containing an alkali metal salt as described in JP-A-3-137221 may be used.
[0056]
Polymers colored with pigments can also be used. The pigment may be either organic or inorganic, but generally, carbon black, bengara, or phthalocyanine pigments are preferably used.
[0057]
Furthermore, additives such as a weather resistance agent, a heat resistance agent, and an antioxidant may be added to the raw material polymer as necessary within a range not impairing the effects of the present invention.
[0058]
The carpet of the present invention is a carpet using the above-described crimped yarn in 80% or more, preferably 90% or more of the pile to be formed.
[0059]
By using 80% or more of the above-mentioned crimped yarn for carpet, it is possible to obtain a carpet that can suppress the generation of warp lines particularly often seen in a single-color cut pile carpet and that has improved covering properties. A carpet composed of a pile surface yarn, a base fabric tufted with the surface yarn, and a backing material attached to the back of the base fabric is a typical carpet form.
[0060]
The carpet of the present invention is highly effective especially for optional carpets, roll carpets and line carpets that require a high-class feeling. Among them, a particularly high effect can be obtained with a non-twisted cut pile in which the vertical stripes are particularly conspicuous and the covering property is important.
[0061]
As described above, a twisted yarn set may be applied to the crimped yarn of the present invention. As a form of the twisted yarn, only a single twist may be applied, or two or three may be combined and various twists composed of a lower twist and an upper twist may be applied.
[0062]
In order to obtain a higher quality carpet as a carpet in the present invention, the above-described carpet crimped yarn of the present invention is used in combination with other filaments as a part of a pile as long as the effect is not impaired. There is no problem. For example, in order to lower the frictional voltage of the carpet, it is possible to mix fibers having antistatic properties.
[0063]
Next, a typical method for producing the crimped yarn for carpet of the present invention will be described.
First, the crimped yarn for carpet of the present invention is basically produced by a known yarn making method. In particular, the molten polymer is obtained by melt spinning and is subsequently produced by a conventional method comprising the steps of cooling, oiling, stretching and crimping.
[0064]
In order to obtain a crimped yarn in which three or more kinds of Y-shaped multifilaments are mixed, which is the greatest feature of the present invention, various methods can be adopted. A method for obtaining three or more types of Y-shaped multi-filaments by providing three or more types of Y-shaped cross-sectional holes in a single spinneret and aligning them during spinning and cooling, and three or more types of Y-shaped A method of obtaining a desired crimped yarn by discharging three or more types of multifilaments separately using a separate die for each cross-sectional multifilament group, and arranging them by winding up. For example, a method in which Y-shaped multifilaments are aligned in a separate process to form a single crimped yarn. From the standpoint of simplicity of process and excellent mixing at the single yarn level, there is a method for obtaining a desired crimped yarn using a die having three or more types of Y-shaped cross-sectional holes in one die. preferable. Of course, the nozzle discharge holes are designed so that the degree of deformation and the single yarn fineness of each group fall within the above-mentioned ranges. Moreover, it is preferable to design the number of holes in each group so that the fineness of the multifilaments in each group is practically the same. Furthermore, the spinning conditions such as the discharge amount, the cooling condition immediately after the discharge, and the take-up speed may be adjusted according to the purpose.
[0065]
As the melt spinning apparatus used in the present invention, both an extruder-type spinning machine and a pressure-type spinning machine can be used, but the former is preferable in terms of product uniformity and yield in the spinning process. In particular, when using an original polymer, an extruder type spinning machine is advantageous.
[0066]
The melt-spun yarn is cooled and lubricated, and then stretched and heat-set as necessary. In stretching, a steam processing device or the like may be used in combination for the purpose of, for example, fixing the stretching point as an auxiliary. In the case of polyamide, since a certain degree of orientation and crystallization are required in order to give a high crimp in a later step, it is usually preferable to perform stretching 2 to 4 times.
[0067]
Next, the obtained drawn yarn is crimped by a crimping device. Crimping may be applied by a normal heated fluid processing. For example, various crimping methods such as a jet nozzle type, a jet stuffer type, and a gear system may be employed. From the surface, a jet stuffer or jet nozzle method is preferred. Of these, the crimp nozzle described in US Pat. No. 3,781,949 is preferably used. Furthermore, for the purpose of fixing crimps, a cooling device described in Japanese Patent Laid-Open No. 5-321058 or a rotary filter may be combined.
[0068]
The obtained crimped yarn for carpet of the present invention can be entangled as necessary for improving the passability in the subsequent step. Entanglement can be imparted by a known method. However, when too much entanglement is imparted to the crimped yarn, the properties of the crimped yarn are impaired and the bulkiness is inhibited as described above.
[0069]
The obtained crimped yarn for carpet of the present invention is twisted and heat-treated depending on the purpose, and any known method can be adopted.
[0070]
Tufting can be performed by a known method. The crimped yarn for carpet of the present invention is particularly effective when tufted as a cut pile, but can be used in various forms such as cut pile, loop pile, cut and loop pile. The pile height of the carpet of the present invention may be appropriately set depending on the application, but a range of 3 mm to 20 mm, more preferably 4 mm to 10 mm is usually selected.
[0071]
Subsequently, staining and backing are performed by a known method. As the dyeing method, continuous dyeing, Wins dyeing, rope dyeing and the like can be used without particular limitation.
[0072]
Of course, when the original yarn is used or when cheese dyeing is performed before tufting, dyeing after tufting can be omitted, and direct backing is performed. In this case, carrying out shearing or splitting as necessary is recommended as a more preferable method.
[0073]
It is also preferable to apply an antifouling agent to the carpet of the present invention in order to enhance the antifouling property.
[0074]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples.
Each physical property value in Examples described below is specifically a value measured by the following method.
[0075]
[Sulfuric acid relative viscosity]
A polymer sample was dissolved in 98% sulfuric acid at a concentration of 1% by weight and measured at 25 ° C. using an Ostwald viscometer.
[0076]
[Total fineness]
Measured according to JIS L 1090.
[0077]
[Total fineness of each group, single yarn fineness]
(When consisting of a single section)
The single yarn fineness was calculated by dividing the total fineness of the crimped yarn by the number of single crimped yarns.
(When two or more groups of multifilaments are mixed)
A cross-sectional photograph of the crimped yarn was taken and enlarged to about A3 size. Next, all the single yarns printed on the copy paper were cut with scissors, and the weight of all single yarns for each group was measured with an electronic balance. The weight of all the single yarns in a group is A, the number of single yarns is B, the weight of all single yarns of crimped yarns is D, and the total fineness of crimped yarns is C.
Total fineness of a certain group = C x A / D
A certain group of single yarn fineness = C × A / (D × B)
Calculated as
[0078]
[Crimp elongation after treatment with boiling water]
A crimped yarn unwound from a package that has been left in an atmosphere at a temperature of 25 ° C. and a relative humidity of 60% for 20 hours is immersed in boiling water for 30 minutes under no load, and then dried to an equilibrium moisture content. Is used as a crimped yarn sample after boiling water treatment. An initial load of 1.8 mg / dtex (2 mg / d) was applied to this sample yarn, and after 30 seconds, a sample length of 50 cm (L ₁ ) Next, after a constant load of 90 mg / dtex (100 mg / d) was applied to the same sample and 30 seconds passed, ₂ ). Next, the crimp elongation rate (%) is obtained by the following formula.
Crimp elongation (%) = [(L ₂ -L ₁ ) / L ₁ ] × 100
Note that the atmosphere condition when the yarn is left before the boiling water treatment is the crimped yarn state when used in the actual carpet manufacturing process, that is, the state where the crimp characteristics have reached an equilibrium state due to moisture absorption. It is selected from the point that it does not take too much time to reach an equilibrium state and no condensation occurs.
[0079]
[Deformation degree]
The cross-sectional photograph of the crimped yarn was enlarged, and the ratio of each diameter of the circumscribed circle and the inscribed circle of the single yarn was taken as the degree of deformation. Each group was calculated as an average value of the measurement of 5 single yarns. When the number of single yarns in the group is 5 or less, the average value of the measurement of all single yarns is used.
[0080]
[Number of confounding]
The number of entanglements per meter was measured visually. Measurement was performed five times in the longitudinal direction of the crimped yarn, and the average value was calculated.
[0081]
[Carpet vertical]
The carpet was placed in a sufficiently bright room with a fluorescent lamp, and the surface of the carpet was observed along the tuft direction of the pile from a location several meters away. And the occurrence situation of the vertical muscle was evaluated as follows relatively. ○ The above is acceptable.
◎ ・ ・ ・ There are no vertical streaks and the surface is uniform and clean.
○: The surface uniformity is slightly inferior to the level of ◎, but there are no vertical stripes.
Δ: There is no clear vertical streak, but there are spots on each pile.
× ... Looks like a streak. Or there are vertical muscles.
[0082]
[Carpet covering]
A carpet was placed in a sufficiently bright room with a fluorescent lamp, and whether or not graininess of piles was observed on the carpet surface was evaluated as follows. ○ The above is acceptable.
A ... Span-like surface appearance without graininess.
○ ・ ・ ・ Inferior to ◎, but not very grainy.
Δ: Although there is a grain feeling, it is a level that does not bother if you look away.
×: Grains are clearly seen in each pile even when viewed from a distance.
[0083]
[Comprehensive evaluation of carpet]
The relative applicability as a carpet was evaluated as follows.
◎… Very good compatibility
○… Good compatibility
Δ: Slightly poor compatibility
X: poor compatibility.
[0084]
[Example 1]
Using one die having discharge holes for three types of Y-shaped cross sections, a nylon 6 chip having a relative viscosity of sulfuric acid of 2.8 is melt-spun with an extruder type spinning machine, and three groups of Y-shaped cross sections Multifilaments were obtained simultaneously. Here, the degree of deformation of the first group is 3.8, the number of single yarns is 32, the degree of deformation of the second group is 3.0, the number of single yarns is 32, the degree of deformation of the third group is 2.4, and the number of single yarns is 32. The three-group discharge hole shape, discharge hole depth, and number of discharge holes are set so that the single yarn fineness of the first, second, and third groups becomes a ratio of 1.57: 1.26: 1.00. Designed. After spinning and solidifying, the three groups of spun yarns are immediately aligned, then refueled, stretched, and subsequently crimped using a known jet stuffer nozzle without further winding, and further entangled Winded up.
[0085]
Thus, the single yarn fineness of the first, second, and third groups is 23.1, 18.4, 14.7, dtex, the fineness of the first, second, and third groups is 740, 590, and 470 dtex, respectively, and the total fineness is 1800 dtex. Of polyamide crimped yarn was obtained. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m.
[0086]
Next, a normal level cut with 1/8 gauge, pile height of 8 mm, and a basis weight of 600 g / m ² The stitch was adjusted so that Thereafter, staining and backing were performed according to a conventional method. Table 1 shows the results of the “vertical”, “covering”, “bulky” and “overall evaluation” of the carpet thus obtained.
[0087]
[Example 2]
The degree of deformation of the first, second and third groups is 4.3, 2.8 and 1.9, respectively, and the ratio of the single yarn fineness of the first, second and third groups is 2.24: 1.50: 1. Example 3 was the same as Example 1 except that the three groups of ejection hole shapes and ejection hole depths were designed to be 00. Thus, the single yarn fineness of the first, second and third groups is 26.6, 17.8 and 11.9 dtex, the fineness of the first, second and third groups is 850, 570 and 380 dtex, respectively, and the total fineness is 1800 dtex. A crimped yarn was obtained. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m. Next, a carpet was obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0088]
[Example 3]
3 so that the deformation degree of the first, second, and third groups is 4.3, 2.8, and 1.9, respectively, and the ratio of the single yarn fineness of the first, second, and third groups is 1: 1: 1. Example 1 was the same as in Example 1 except that the shape and depth of the discharge holes of the group were designed.
Thus, polyamide crimped yarns having a single yarn fineness of the first, second and third groups of 18.8 dtex and a fineness of both the first, second and third groups of 600 dtex and a total fineness of 1800 dtex were obtained. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m. Next, a carpet was obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0089]
[Example 4]
The degree of deformation of the first, second and third groups is 3.0, the number of single yarns of the first, second and third groups is 22, 36 and 50, respectively, and the single yarn fineness of the first, second and third groups. Example 3 was the same as Example 1 except that the three groups of ejection hole shapes, ejection hole depths, and number of ejection holes were designed so that the ratio of A was 2.27: 1.38: 1. Thus, the first, second, and third groups have a single yarn fineness of 27.3, 16.7, and 12.0 dtex, and the first, second, and third groups have a fineness of 600 dtex, respectively, and a polyamide crimped yarn having a total fineness of 1800 dtex. Got. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m. Next, a carpet was obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0090]
[Example 5]
Using one die having four types of discharge holes for Y-shaped cross section, the deformation degree of the first, second, third, and fourth groups is 4.4, 3.3, 2.5, and 2.0, respectively. The number of single yarns of the first, second, third and fourth groups is 24, and the single yarn fineness of the first, second, third and fourth groups is 1.00: 1.31: 1.69: 2.21. Except that the four groups of discharge hole shapes, discharge hole depths, and the number of discharge holes were designed so as to achieve a ratio, the same procedure as in Example 1 was performed. Thus, the single yarn fineness of the first, second, third, and fourth groups is 12.1, 15.8, 20.4, and 26.7 dtex, respectively, and the fineness of the first, second, third, and fourth groups is 290, 380, and 490, respectively. , 640 dtex, and a polyamide crimped yarn having a total fineness of 1800 dtex was obtained. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m. Next, a carpet was obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0091]
[Example 6]
The degree of deformation of the first, second, third and fourth groups is 4.0, 4.0, 2.0 and 2.0, respectively, and the number of single yarns of the first, second, third and fourth groups is 16, 32 and 16 respectively. , 32, and four groups of discharge hole shapes and discharge holes so that the ratio of the single yarn fineness of the first, second, third, and fourth groups is 2.0: 1.0: 2.0: 1.0 Example 5 was the same as in Example 5 except that the depth and the number of ejection holes were designed. Thus, the single yarn fineness of the first, second, third and fourth groups is 28.1, 14.1, 28.1 and 14.1 dtex, respectively, and the fineness of the first, second, third and fourth groups is 450 dtex, A polyamide crimped yarn having a total fineness of 1800 dtex was obtained. The crimped elongation of the obtained crimped yarn after boiling water treatment was 15%, and the number of entanglements was 10 / m. Next, a carpet was obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0092]
As is apparent from the results in Table 1, in the examples of the present invention, all of the vertical lines, covering properties and comprehensive evaluation of the carpet were satisfactory. Particularly in Example 3, the three groups had the same single yarn fineness, and the covering property was good. In Example 4, the three groups had the same degree of deformation, and the warp was good. In Example 6, the four groups including two types of deformation and two types of single yarn fineness were mixed, and both the warp and covering properties were good.
[0093]
[Comparative Examples 1-5]
In Example 1, the case of using a die whose discharge hole was designed so as to consist of only one group having a degree of deformation of 3.0 and a number of single yarns of 96 was designated as Comparative Example 1. Thus, a polyamide crimped yarn having a single yarn fineness of 18.8 dtex and a total size of crimped yarn of 1800 dtex was obtained.
[0094]
In Example 1, the degree of deformation of the first and second groups is 4.0 and 2.0, the number of single yarns of the first and second groups is 48, and the single yarn fineness of the first and second groups. Comparative Example 2 was used in the case of using a base in which the discharge hole shape, the discharge hole depth, and the number of discharge holes were designed so as to consist of two groups with a ratio of 1: 1.
[0095]
In Example 1, the degree of deformation of the first, second, and third groups is 3.5, 3.0, and 2.6, respectively, and the number of single yarns of the first, second, and third groups is 28, 32, and 36, respectively. In addition, a case is used in which a die designed with the discharge hole shape and discharge hole depth of the third group so that the ratio of the single yarn fineness of the first, second, and third groups is 1.29: 1.13: 1.00. It was set as Comparative Example 3.
[0096]
In Example 4, the degree of deformation of the first, second, third and fourth groups is 3.2, 3.2, 2.8 and 2.8, respectively, and the number of single yarns of the first, second, third and fourth groups is The discharge of the four groups so that the ratio of the single yarn fineness of the first, second, third, and fourth groups is 1.18: 1.00: 1.18: 1.00 on 22, 26, 22, and 26, respectively. The case where a base designed with a hole shape, a discharge hole depth, and the number of discharge holes was used was referred to as Comparative Example 4.
[0097]
Next, carpets were obtained from the crimped yarns obtained in the same manner as in Example 1. The evaluation results of the carpet are shown in Table 1.
[0098]
[Table 1]

[0099]
In Comparative Example 1, since it is a crimped yarn composed of a normal single section, the warp and covering properties were particularly poor. In Comparative Example 2, since two different groups were mixed, the vertical and covering properties were poor. In Comparative Example 3, the difference in the degree of deformation and single yarn fineness among the three groups was insufficient, and the warp and covering properties were poor. In Comparative Example 4, the difference in the degree of deformation and the single yarn fineness between the four groups was insufficient, and the warp and covering properties were poor.
[0100]
【The invention's effect】
The crimped yarn for carpet according to the present invention can suppress the generation of warp lines often seen particularly in a single-color cut pile carpet and can provide a carpet with good covering properties. In addition, the carpet of the present invention makes use of the characteristics of the above-mentioned crimped yarn for carpet as it is, and is particularly suitable as an option carpet, a roll carpet, and a line carpet.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a Y-shaped multi-filament constituting a crimped yarn of the present invention.
FIG. 2 is a schematic view illustrating an inscribed circle and a circumscribed circle used for measuring the degree of deformation of a Y-shaped cross-section single yarn.
[Explanation of symbols]
1: Inscribed circle
2: circumscribed circle

Claims (11)

A crimped yarn in which three or more groups of Y-shaped cross-sectional multifilaments having at least one of deformation degree and single yarn fineness different between any two groups are mixed, and the polymers constituting the crimped yarn are the same regardless of the group A crimped yarn for carpet characterized in that. 2. The crimped yarn for carpet according to claim 1, wherein all groups have the same degree of deformation. The crimped yarn for carpet according to claim 1, wherein all groups have the same single yarn fineness. The crimped yarn for carpet according to any one of claims 1 to 3, wherein the mixed Y-shaped multifilaments are in 3 groups or 4 groups. It is a crimped yarn in which four different groups of Y-shaped multifilaments are mixed, and the first group of deformation M1, single yarn fineness T1, the second group of deformation M2, single yarn fineness T2, the third group of The crimp for a carpet according to claim 1, wherein the degree of deformation M3, the single yarn fineness T3, the degree of deformation M4 of the fourth group, and the single yarn fineness T4 are in the range of the following formulas (1) to (6). yarn.
(1) 1 / 1.15 ≦ M2 / M1 ≦ 1.15
(2) 1 / 1.15 ≦ M4 / M3 ≦ 1.15
(3) 1 / 1.15 ≦ T3 / T1 ≦ 1.15
(4) 1 / 1.15 ≦ T4 / T2 ≦ 1.15
(5) 1.2 ≦ Mk / Ml
(Established by any combination of k = 1, 2, 1 = 3,4)
(6) 1.2 ≦ Tk / Tl
(Established by any combination of k = 1, 3, l = 2, 4) The crimped yarn for carpet according to any one of claims 1 to 5, wherein the fineness of each multifilament group is substantially the same. The total fineness is 600 to 2000 dtex, the crimp elongation after treatment with boiling water is 5 to 28%, and the number of entanglements is 20 / m or less, for carpets according to any one of claims 1 to 6 Crimped yarn. The crimped yarn for carpet according to any one of claims 1 to 7, wherein the polymer constituting the crimped yarn is polyamide. A carpet characterized in that the crimped yarn for carpet according to any one of claims 1 to 8 is used for 80% or more of a pile constituting the carpet. The carpet according to claim 9, wherein the carpet is any one of an optional carpet, a roll carpet, and a line carpet. The carpet according to claim 9 or 10, wherein the pile is untwisted and is a cut pile.

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