JPH11113722A - 3-grandrelle tone carpet and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a 3-Grandrelle tone carpet which has the patterns larger than the patterns of a carpet having the patterns of the conventional 2- Grandrelle or 3-Grandrelle tone and has a good 3-color feel and a process for efficiently producing the 3-Grandrelle tone carpet. SOLUTION: Arbitrary two kinds of the 2-Grandrelle yarn selected from several kinds of the 2-Grandrelle yarn formed by aligning, intertwining or twisting arbitrary two kinds of crimped yarn of >=5 <15% in elongation rate difference among three kinds of the crimped yarn varying in dyeing properties are subjected to tuft flocking and dyeing treatment on a base fabric so as to be adjacent to each other in this 3 Grandrelle tone carpet. The crimped yarn consists of polyamide and the fineness of the 2-Grandrelle yarn is preferably 20,000 to 40,000 denier.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet having three heathers using crimped yarn as a face yarn and a method for producing the same, and more particularly, to a carpet having the same area occupied by three colors and having a large handle. Contrast between the three colors (below
The present invention relates to a three heather-like carpet having good three-color appearance and expression) and a method for efficiently producing the three heather-like carpet.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for quality improvement and cost reduction of carpets using crimped yarns as face yarns.

[0003] Particularly in the field of tiles and roll carpets,
Under the condition that the fineness of the heather thread and the basis weight of the carpet (the amount of the original yarn per unit area) are not changed, the color tone is more complicated (three heather tone) than the conventional two heather tone carpet, and the three-color carpet is good. There is a strong demand for inexpensive raw yarns that can be manufactured.

[0004] In order to meet the above-mentioned demands, a conventional carpet having a pattern of three heathers has a so-called three-kind yarn obtained by entangled or twisted three kinds of crimped yarns having three different dyeing performances. Heather yarn was used as the original yarn.

[0005] However, in the above prior art,
The pattern is small to make three heather patterns with one heather thread.
There is a drawback that a carpet having insufficient color contrast (hereinafter referred to as three-color feeling) is finished. Further, since the fineness of the three crimped yarns constituting the three heathered yarns is small, there is a disadvantage that the production cost of the three heathered yarns increases.

[0006]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in the prior art, and as a result,
Has been achieved.

Accordingly, an object of the present invention is to provide a three-heater carpet having a larger pattern and a better three-color appearance than a conventional carpet having a two-heater or three-heater-like pattern, and to efficiently manufacture the three-heater-like carpet. How to do it.

[0008]

Means for Solving the Problems In order to achieve the above-mentioned object, the three-layered carpet of the present invention mainly has the following constitution. That is, any three of the three types of crimped yarns having different dyeing properties, each having an elongation rate difference of 5% or more and less than 15%.
Any two types of two heather yarns selected from several types of two heather yarns obtained by aligning and entangled or twisting different types of crimp yarns are tufted into a base cloth so that they are adjacent to each other, and dyed. It is a three heather-like carpet characterized by being made.

In the multi-carpet carpet of the present invention, it is desirable that the fineness of the two heat-treated yarns is 2000 to 4000 denier, respectively, and that the crimped yarn is made of polyamide. A more excellent effect can be obtained by applying.

[0010] The method for producing a three-layered carpet of the present invention has one of the following structures. That is, three types of crimped yarns having different dyeing properties are prepared in advance, and any two types of crimped yarns having a difference in elongation ratio of 5% or more and less than 15% are selected from the three types, and are tangled and entangled. An arbitrary two kinds of two heather yarns are selected from several kinds of two heather yarns obtained by twisting, and the two kinds of two heather yarns are tufted into a base cloth so that they are adjacent to each other, and then dyed. A method of manufacturing a three-heater carpet, or any two types of crimped yarns having a difference in elongation percentage of 5% or more and less than 15% among three types of yarn-dyed crimped yarns having different colors. Is selected, and any two kinds of two heather yarns are selected from several kinds of two heather yarns obtained by aligning and entanglement processing or twisting, so that these two heather yarns are adjacent to each other. A method for producing a three-heater-like carpet, which comprises tufting hair into a base cloth.

In the production method of the present invention, the dyeing properties are different.
Various kinds of crimped yarns are prepared in advance, and any two of which have different dyeing properties and a difference in elongation percentage of 5% or more and less than 15%.
Any two kinds of two heather yarns are selected from three kinds of two heather yarns obtained by selecting a kind of crimped yarn, and arranging and entanglement processing or twisting these two kinds of two heather yarns. By tufting the base cloth so as to be adjacent to each other and then performing a dyeing treatment, a carpet having three heathers can be efficiently manufactured. Further, a yarn-dyed crimped yarn may be used instead of the crimped yarn.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.

The three heather carpet of the present invention has a difference in elongation rate of 5% or more and 15% among three types of crimped yarns having different dyeing properties.
Select any two types of crimped yarns that are less than, select any two types of different combinations from the combination of several types of two heather yarns obtained by aligning and entanglement processing or twisting, This is a three-carpet-like carpet in which these two types of two heather threads are tufted into a base cloth so that they are adjacent to each other, and then dyed. In the present invention, two types of two heather yarns are made from three types of crimped yarns, and the two heather yarns are tufted into a base cloth so as to be adjacent to each other to produce a carpet. But two kinds of 2
The number of crimped yarns constituting the heather yarn becomes four, and one of the three heather yarns is always included in the two heather yarns. That is, if the appearance probabilities of the colors appearing on the surface of the two crimped yarns after dyeing are not controlled, one color becomes a conspicuous striped carpet. The present inventor considered controlling the appearance probability of this color by the difference in the elongation rate of the crimped yarn. That is, by providing a difference in elongation between the crimped yarns constituting the two heather yarns,
(2) Since the crimped yarn having a low elongation ratio partially covers the crimped yarn having a high elongation ratio, the color of the crimped yarn having a low elongation ratio appears rich on the surface of the yarn after dyeing. Further, by setting the difference in the elongation rate of the crimped yarn to 5% or more and less than 15%, the appearance probability of the color of the crimped yarn having a low elongation rate and the color of the crimped yarn having a high elongation rate appearing on the surface of the yarn after dyeing can be determined, for example. It can be controlled as 2: 1. Here, by designing the quality of the crimped yarn commonly included in the two types of two heather yarns to be higher than that of the other crimped yarn by 5% or more and less than 15%,
The appearance probability of the color of the crimped yarn commonly included in the two types of two heather yarns is halved. That is, in the completed carpet, the appearance probabilities of the colors of the three crimped yarns are the same, giving a good three-color appearance. In the present invention, two 2
In order to express three colors with heather threads, the area occupied by each color is larger than when three colors are expressed with one conventional heather thread. That is, the pattern becomes large. Further, since the fineness of the two heather yarns of the present invention is set to about 1.5 times or more the fineness of the conventional three heather yarns, productivity is improved.

In the present invention, in the case of polyamide, the polymer used as the raw material of the crimped yarn having different dyeing performance is a method of controlling the amount of amino terminal groups and carboxyl terminal groups in a polymerization or spinning process, and a method of controlling sulfone groups. For example, it can be formed by a method of introducing a functional group other than the terminal group of the polyamide in the polymerization or spinning step.

A polymer colored with a pigment may be used.

The two yarns composed of two kinds of crimped yarns having different dyeing properties used in the present invention are, for example, in the case of two yarns of nylon 6, a fiber composed of a polymer having a large number of NH _{2 end} groups dyed with an acid dye. Two different colors are dyed in combination with a fiber composed of a polymer having a large amount of SO ₃ end groups, which is dyed with a basic dye.

In the present invention, the fineness of each of the heathered yarns is desirably 2000 to 4000 denier from the viewpoint of maintaining good feeling when carpeted.

Next, a method for producing the three-layered carpet of the present invention will be described.

First, in obtaining two heather yarns composed of two kinds of crimped yarns having different dyeing properties, for example, two kinds of polymers having different dyeing properties are melt-spun from independent spinning machines and then cooled. After cooling and solidifying, and subsequently applying an oil agent, the undrawn yarn is taken up by a take-up roll rotating at 300 to 1200 m / min.
Stretch at up to 6 times. Subsequently, each drawn yarn is processed into a crimped yarn using a conventionally known crimping device using a heating fluid, for example, the device described in Japanese Patent Publication No. 58-1214, and US Pat. No. 4,526,808. 2 obtained
What is necessary is just to air-entangle processing or twist a kind of crimped yarn.

Here, two types of polymers having different dyeing properties may be melt-spun by independent spinning machines and then combined before drawing, but are desirably simultaneously combined at the stage of entanglement after crimping. By thread entanglement, the three-color appearance in the case of a carpet becomes better.

By the above method, two heather yarns are obtained.

Next, the two types of two heather yarns obtained by the above method were set on a tufting machine, and tufted into a primary backing made of a polyester non-woven fabric, for example, so that the two heather yarns were adjacent to each other. After that, a dyeing treatment is performed, and a backing is performed as necessary, whereby the three-heated carpet of the present invention can be obtained. In addition, when performing tuft flocking, it is preferable to mix antistatic yarn alternately, because static electricity can be suppressed.

If two types of two heather yarns are not tufted next to each other, two heather yarns of the same color will be adjacent to each other, so that the pattern becomes monotonous or streaky. The pattern characteristics of three heathers cannot be obtained.

In the conventional technique described above, one crimped yarn having three different dyeing performances is used for one heather yarn, whereas in the present invention, two heather yarns are used in the present invention. In order to represent three colors, the area occupied by each color is larger than in the case where three colors are represented by one conventional two heather thread. That is, the pattern becomes large and the three-color appearance is improved. Further, since the fineness of the two heather yarns of the present invention is set to about 1.5 times or more the fineness of the conventional three heather yarns, productivity is improved.

[0025]

EXAMPLES The present invention will be described below with reference to examples.

Each physical property in the present invention is a value determined as follows.

<Amino group content> The phenolethanolamine was added to the sample to dissolve it, and the content was determined by titration with hydrochloric acid.

<Amount of carboxyl group> A sample was added with benzyl alcohol and dissolved by heating, and the content was determined by titration with a KOH alcohol solution.

<Amount of sulfone group> After dissolving the sample by adding formic acid, it was determined by measuring UV absorption at 285 nm.

<Crimping elongation> The crimped yarn was de-skewed,
After releasing at 65 ° C. for 3 hours, boiled with water for 20 minutes, and then air-dried for 12 hours, the yarn length when an initial load of 2 mg / d was applied for 30 seconds was L1, and the constant load was 100 mg / d for 30 seconds. When the yarn length at the time of threading is L2, the length is calculated by the following equation. ((L2-L1) / L1) x 100 <Three colors of carpet (contrast)> Carpet products are visually judged by 20 monitors, and the feeling of heat (contrast) is judged. The one with the best feeling of heat (contrast) is grade 3 and the worst is the grade 1.

<Carpet Streaks>
Have a human monitor visually determine the streak. The class with the least streak is grade 3 and the one with the most striking streak is grade 1.

[Examples 1 to 3, Comparative Example 1] Three types of nylon 6 polymers having different dyeing performances shown in Table 1 (a polymer having a large number of NH ₂ end groups dyed by an acid dye to give a color shade) , A polymer having a small number of NH ₂ terminal groups and a polymer having a large number of SO ₃ terminal groups to be dyed by a basic dye), respectively, are melted by an extruder spinning machine, and the hollow fibers having a hollow ratio of 12% from a hollow cross section die are obtained. Was spun.

An oil agent was first adhered to the yarn obtained from the spinning section, subsequently taken up by a take-up roll, and drawn by a heating draw roll to obtain a multifilament. Further continuously, by performing a heating steam treatment in a crimping device described in U.S. Pat. No. 4,526,808, and applying a crimp, after winding in a cheese shape, having a different dyeing performance, Fineness: 1300 denier, number of filaments: 80, hollow porosity of 12%, crimp elongation: A polymer:
15%, B polymer: 22%, C polymer: 28%
Various kinds of crimped yarns were obtained. Subsequently, two types of crimped yarns were selected, and these crimped yarns were aligned and simultaneously air-entangled to obtain two types of two heather yarns. The two heather yarns obtained by the above method are set on a tufting machine, and two kinds of heather yarns are tufted on the primary base cloth of the polyester non-woven fabric so that the two heather yarns are adjacent to each other. Was. That is, there are three ways to select two types of two heather yarns from three types of two heather yarns, and thus three types of three heather-like carpets were obtained.

Each of the obtained carpets had a large handle, a good three-color appearance, and no streaks.

Tables 1 and 2 show the results. Table 2 shows a conventional yarn as Comparative Example 1.

[0036]

[Table 1]

[Table 2] Here, in the conventional yarn of Comparative Example 1, three kinds of nylon 6 polymers (A, B and C) similar to those of Example 1 were melted by an extruder type spinning machine, respectively, and the hollow ratio was higher than that of a hollow type cross section die. 12% of hollow fibers were spun. An oil agent was first adhered to the yarn obtained from the spinning section, subsequently taken up by a take-up roll, and drawn by a heating draw roll to obtain a multifilament. More continuously, U.S. Pat.
No. 26808, a heating steam treatment is performed by a crimping device described in the specification, and after imparting a crimp, it is wound into a cheese shape, thereby having a different dyeing performance, each having a fineness of 870 denier, a filament number of 54, Cone hollow ratio 12%, crimp elongation ratio: A polymer: 22%, B polymer: 22%, C
Polymer: Three types of crimped yarns of 22% were obtained. Next, three kinds of crimped yarns are aligned and simultaneously air-entangled, and three heather yarns are set on a tufting machine. After tufting on a primary fabric of a polyester nonwoven fabric, a dyeing treatment and a backing are performed. Got a carpet.

[Comparative Examples 2 to 4] The same three types of nylon 6 polymers (A, B and C) as in Example 1 were each melted by an extruder type spinning machine, and the hollow ratio was obtained from a hollow cross section die. Spun hollow fibers of 12%. An oil agent was first adhered to the yarn obtained from the spinning section, subsequently taken up by a take-up roll, and drawn by a heating draw roll to obtain a multifilament. Further continuously, by performing a heating steam treatment in a crimping device described in U.S. Pat. No. 4,526,808, and applying a crimp, after winding in a cheese shape, having a different dyeing performance, Fineness 13
00 denier, 80 filaments, 12 hollows
%, Crimp elongation: A polymer: 19%, B polymer: 2
Three types of crimped yarns of 1% and C polymer: 23% were obtained. Subsequently, two kinds of crimped yarns are selected, and these crimped yarns are aligned and simultaneously air-entangled to obtain two kinds of crimped yarns.
A heather thread was obtained. The two heather yarns obtained by the above method are set in a tufting machine, and two kinds of heather yarns are tufted on a primary fabric of a polyester non-woven fabric so that the two heather yarns are adjacent to each other.
The carpet was obtained by backing. In other words, there are three ways to select two types of two heather yarns from three types of two heather yarns.
Three types of heather-like carpets were obtained.

Each of the obtained carpets had a large pattern and good three-color appearance, but had noticeable streaks and was unsuitable as a commercial product. Table 3 shows the results.

[0039]

[Table 3] [Comparative Examples 5 to 7] Three types of nylon 6 similar to those in Example 1.
The polymers (A, B and C) were each melted by an extruder type spinning machine, and a hollow fiber having a hollow ratio of 12% was spun from a hollow cross section die. An oil agent was first adhered to the yarn obtained from the spinning section, subsequently taken up by a take-up roll, and drawn by a heating draw roll to obtain a multifilament. More continuously, US Pat.
No. 8, a heat-steaming treatment is performed by a crimping apparatus described in the specification, and after crimping is applied, it is wound into a cheese shape, thereby having a different dyeing performance, a fineness of 1300 denier, a filament number of 80, respectively. Three types of crimped yarns were obtained, each having a hollow hollow ratio of 12%, a crimp elongation ratio of A polymer: 10%, a B polymer: 27%, and a C polymer: 10%. Subsequently, two types of crimped yarns were selected, and these crimped yarns were aligned and simultaneously air-entangled to obtain two types of two heather yarns.
The two heather yarns obtained by the above method are set on a tufting machine, and two kinds of heather yarns are tufted on the primary base cloth of the polyester non-woven fabric so that the two heather yarns are adjacent to each other. Was. That is, there are three ways to select two types of two heather yarns from three types of two heather yarns, and thus three types of three heather-like carpets were obtained.

Each of the obtained carpets had a large pattern and good three-color appearance, but had noticeable streaks and was unsuitable as a commercial product.

Table 4 shows the results.

[0042]

[Table 4]

[0043]

As described above, the three heathered carpet of the present invention has a larger pattern than the conventional three heathered carpet.
There is a sense of color. Further, according to the method for manufacturing a three-heated carpet of the present invention, it is possible to manufacture the carpet with higher productivity than the conventional three-heated carpet.

Claims (6)

[Claims] Claims 1. An arbitrary two types of crimped yarns having a difference in elongation ratio of 5% or more and less than 15% among three types of crimped yarns having different dyeing properties, and are tangled or twisted to obtain several types. A three heather-like carpet, characterized in that two arbitrary heather yarns selected from two heather yarns are tufted into a base cloth and dyed so that they are adjacent to each other. 2. The three heather-finished carpet according to claim 1, wherein the crimped yarn is made of polyamide. 3. The three heather-like carpet according to claim 1, wherein the fineness of the two heather yarns is 2,000 to 4,000 denier. 4. The three heather-finished carpet according to claim 1, wherein the crimped yarn has a cross section in the shape of a hollow, and the ratio of the hollow portion is 5 to 20%. 5. Three kinds of crimped yarns having different dyeing properties are prepared in advance, and any two kinds of crimped yarns having a difference in elongation ratio of 5% or more and less than 15% are selected from among them, and they are aligned. Arbitrary 2 out of several types of 2 heather yarns obtained by entanglement or twisting
A method for producing a three-heater carpet, comprising selecting two types of heather yarns, tufting the base cloth so that these two types of heather yarns are adjacent to each other, and then dyeing. 6. An arbitrary two types of crimped yarns having an elongation difference of 5% or more and less than 15% are selected from among three types of yarn-dyed crimped yarns having different colors, and the yarns are aligned and entangled or twisted. An arbitrary two kinds of two heather yarns are selected from several kinds of two heather yarns obtained by the above process, and tufting is performed on the base cloth such that these two heather yarns are adjacent to each other. 3 Method of manufacturing heather-like carpet.