JPH11164767A - Gradnrelle carpet with three differential dyeing firers and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-grandrelle carpet which has patterns larger than conventional carpets having two or three-grandrelle patterns, and which provides a good feeling of three colors and to provide a method for efficiently manufacturing the three grondrelle carpet. SOLUTION: Two kinds of two-grandrelle yarns, selected from several kinds of two-grandrelle yarns obtained when, of three kinds of crimped yarns of different dyabiolity, two kinds of crimped yarns which differ in fineness by to less than 10% and not more than 105% are aligned and interwoven or twisted together, are mode to tuft a ground fabric in such a way as to adjoin to each other and are dyed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a three heather carpet using crimped yarn as a face yarn and a method for producing the same. Contrast (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 two of the three types of crimped yarns having different dyeing properties, each having a fineness difference of 10% or more and 105% or less.
It is selected from several types of two heather yarns obtained by aligning and entangled or twisting different types of crimp yarns, and any two types of heather 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.

The method for producing a three-layered carpet according to the present invention has one of the following constitutions. That is, three types of crimped yarns having different dyeing properties are prepared in advance, and any two types having a fineness difference of 10% or more and 105% or less are selected from the three types, and the two types are aligned and entangled or twisted. It is characterized by selecting any two kinds of two heather yarns from the combination of several kinds of two heather yarns, tufting the base cloth so that these two heather yarns are adjacent to each other, and then dyeing. A method of manufacturing a three heather-like carpet, or selecting any two types of crimped yarns having a fineness difference of 10% or more and 105% or less from three types of yarn-dyed crimped yarns of different colors, An arbitrary two types of two heather yarns are selected from a combination of several types of two heather yarns obtained by aligning and entanglement processing or twisting, and the base cloth is arranged so that these two heather yarns are adjacent to each other. And a tuft-flocked carpet.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the present invention will be described below.

[0011] From among three types of crimped yarns having different dyeing properties, several types of two heathers obtained by arranging any two types of crimped yarns having a fineness difference of 10% or more and 105% or less and entangled or twisted. This is a three heather-like carpet that is selected from yarns, and two types of two heather yarns are tufted into a base cloth so that two arbitrary heather yarns 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,
These are tufted into a base cloth so as to be adjacent to each other to produce a carpet. However, the number of crimped yarns constituting the two types of two heather yarns is four, and one of the three types is always two.
It will be included in two types of heather yarn. That is, if two crimped yarns out of two heather yarns do not control the appearance probability of the color appearing on the surface of the yarn after dyeing, one color becomes a conspicuous striped carpet. The inventor has considered controlling the appearance probability of this color by the difference in fineness of the crimped yarn. That is, by providing a fineness difference between the crimped yarns constituting the two heathered yarns, it is possible to control the appearance probability of a color in which two crimped yarns of the two heathered yarns appear on the yarn surface after dyeing. As a result of intensive studies, the inventor has found that by setting the difference in fineness to 10% or more and 105% or less, a carpet with less noticeable stripes after dyeing can be obtained. Here, the fineness difference between the two types of two heather yarns is a value obtained by the following formula. Fineness of the crimped yarn A: a Fineness of the crimped yarn B: ba When b> b Fineness difference (%) = ((ab) / b) × 100 In the present invention, two two heather yarns are used. 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. Furthermore, since the fineness of the two heather yarns of the present invention is set to 1.5 times the fineness of the conventional three heather yarns, productivity is improved.

In the present invention, in the case of polyamide, the polymer as a raw material of the crimped yarn having different dyeing performance is a method for controlling the amount of amino terminal groups and the amount of carboxyl terminal groups in a polymerization or spinning step, and a method for 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.

Further, a polymer colored with a pigment may be used.

The two heat-treated 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 heat-treated 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 the heather yarn is desirably from 2,000 to 4,000 denier, and if it is less than 2,000 denier or more than 4,000 denier, the feeling when carpeted is deteriorated, which is not preferable. Next, a method for manufacturing 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, two kinds of polymers having different dyeing properties are melt-spun from independent spinning machines and then cooled by cold air. After solidification and subsequent attachment of an oil agent, the oil is taken up by a take-up roll rotating at 300 to 1200 m / min, and the undrawn yarn is drawn 2 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. The obtained two types of crimped yarns are aligned and entangled with a fluid such as air or steam, or twisted.

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.

[0018] Two heather yarns are obtained by the above method.

Next, two kinds of two heather yarns obtained by the above method are set on a tufting machine, and two kinds of two heather yarns are tufted into a primary base cloth of a polyester nonwoven fabric so that the two heather yarns are adjacent to each other. By performing backing, and if necessary, the three heather-like carpet of the present invention can be obtained. When tufting is performed, static electricity can be suppressed by alternately mixing antistatic yarn.
If two types of 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. It is not preferable because heather-like pattern characteristics cannot be obtained.

In the above-mentioned conventional technique, one heat-treated yarn uses three types of crimped yarns having three types of different dyeing performances, whereas in the present invention, two two heat-treated yarns have three colors. The area occupied by each color is larger than that in the case where three colors are expressed by one conventional two heather yarns in order to express. That is, the pattern becomes large and the three-color appearance is improved. Furthermore, since the fineness of the two heather yarns of the present invention is set to 1.5 times the fineness of the conventional three heather yarns, productivity is improved.

[0021]

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

The physical properties in the examples described above and below are values obtained as follows.

<Amino group content> The sample was dissolved by adding phenolethanolamine and titrated with hydrochloric acid.

<Amount of carboxyl group> After adding benzyl alcohol to the sample and dissolving it by heating, it was determined by titration with a KOH alcohol solution.

<Amount of sulfone group> The sample was added with formic acid and dissolved, and the UV absorption at 285 nm was measured. <Crimping elongation> The crimped yarn was crushed, shrunk at 20 ° C. and 65% for 3 hours, treated with boiling water for 20 minutes, air-dried for 12 hours, and then subjected to an initial load of 2 mg / d for 30 seconds. When the yarn length at this time is L1, and the yarn length when a constant load of 100 mg / d is applied for 30 seconds is L2 ((L2−L1) / L1) x
100.

<Three colors (contrast) of carpet>
The carpet product is visually judged by a monitor of 20 persons, and a feeling of heather (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.

[Example 1, 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 with an acid dye in order to impart a light and dark color; _{(2) A} polymer having a small number of terminal groups and a polymer having a large number of SO ₃ terminal groups which are dyed by a basic dye) are melted by an extruder type spinning machine, respectively, and a hollow fiber having a hollow ratio of 12% is spun from a hollow cross-section die. did.

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 filament number: 80, hollow shape rate: 12%, elongation at crimp: 22%, fineness: A polymer: 125
0D, B polymer: 1750D, C polymer: 1750
Thus, three types of crimped yarns D were obtained. At this time, the difference in size between the A polymer and the B polymer was 40%, and the difference in size between the A polymer and the C polymer was 40%. Subsequently, two types of crimped yarns (combinations of A polymer and B polymer and A polymer and C polymer) are selected, and these crimped yarns are aligned and simultaneously air-entangled to form two types of two heather yarns. Obtained.
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. Each of the obtained carpets had a large handle, a good three-color appearance, and no streaks. Table 1, Table 2
Shows the results.

[0030]

[Table 1]

[Table 2] Here, the conventional yarn of Comparative Example 1 was prepared by melting three types of nylon 6 polymers (A, B and C) as in Example 1 using an extruder type spinning machine, and having a hollow ratio 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. 526808, a steaming treatment is performed by a crimping apparatus described in the specification, and after crimping is applied, the film is wound into a cheese shape, thereby having a different dyeing performance, and each having a fineness of 100.
0 denier, 54 filaments, 12% hollow hollow,
Three types of crimped yarns having a crimp elongation 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.

[Examples 2 and 3] The same three kinds 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. Fineness filament number 80, hollow shape 12%, crimp elongation 22
%, Fineness: A polymer: 1000D, 1400D, B polymer: 2000D, 1600D, C polymer: 200
Six types of crimped yarns of 0D and 1600D were obtained. Continued
Select two types of crimped yarns, align these crimped yarns,
At the same time, two types of two heather yarns were obtained by air entanglement treatment. 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. Each of the obtained carpets had a large handle, a good three-color appearance, and no streaks. Table 3 shows the results.

[0032]

[Table 3] [Comparative Examples 2 and 3] Three types of nylon 6 similar to 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 steaming treatment is performed by a crimping apparatus described in the specification, and after crimping is applied, the resultant is wound into a cheese shape, thereby having a different dyeing performance and each having a fineness filament number of 8
0, rice-shaped hollow rate 12%, crimp elongation rate 22%, fineness: A polymer: 900D, 1500D, B polymer: 2100
D, 1500D, and C polymers: Six types of crimped yarns of 900D and 1500D 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,
After tufting the primary base fabric of the polyester non-woven fabric so that the heather yarns are adjacent to each other, a dyeing treatment and a backing were performed to obtain a carpet. Each of the obtained carpets had a large pattern and a good three-color appearance, but had noticeable streaks and was unsuitable as a commercial product. Table 4 shows the results.

[0033]

[Table 4]

[0034]

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] [Claim 1] From among three types of crimped yarns having different dyeing properties, any two types of crimped yarns having a fineness difference of 10% or more and 105% or less are aligned and entangled or twisted to obtain several types. A three heather-finished carpet, wherein two arbitrary heather yarns selected from two heather yarns are tufted into a base fabric and dyed so that two arbitrary heather yarns are adjacent to each other. 2. The three heather-finished carpet according to claim 1, wherein the crimped yarn is a 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 cross-sectional shape of the crimped yarn is a hollow portion having a cross shape,
The three-heated carpet according to any one of claims 1 to 3, wherein the proportion 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 having a fineness difference of 10% or more and 105% or less are selected from them, and they are aligned and entangled or twisted. Two kinds of two heather yarns are selected from the combination of several kinds of two heather yarns obtained by the above, and these two two heather yarns are tufted into a base cloth so that they are adjacent to each other, and then dyed. A method for producing a three heather-like carpet, comprising: 6. An arbitrary two types of crimped yarns having a fineness difference of 10% or more and 105% or less are selected from three types of yarn-dyed crimped yarns having different colors, and the yarns are aligned and entangled or twisted. It is characterized by selecting any two kinds of two heather yarns from the combination of several kinds of two heather yarns obtained and performing tufting on the base cloth such that these two heather yarns are adjacent to each other. 3. A method for producing a heather-like carpet.