JPH1193050A - Silky-toned pile fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prepare the subject fabric with pile falling phenomena obviated, hard to develop bleached appearance, having soft feeling, and suitable for interior trimming or the like, by including pile yarns constituted mainly of a specific polytrimethylene terephthalate and having each specific single fiber crimp pitch and crimp extensibility. SOLUTION: This silky-toned pile fabric is obtained by including a pile yarn >=90 wt.% of which is constituted of a polytrimethylene terephthalate. The pile yarn has a single fiber crimp pitch of 500-2,000 μm and crimp extensibility of <=10%. It is preferable that the polytrimethylene terephthalate fiber has a tenacity of 2.5-4.5 g/d, elongation at break of 25-45%, elastic modulus of 20-50 g/d, and elastic recovery of 70-90% when extended at 20%.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a pile fabric containing a pile material composed of polyester fibers. More specifically, at least 90% by weight is composed of polytrimethylene terephthalate, the single yarn crimp pitch is 500 to 2000 μm, and the crimp elongation is 1
The present invention relates to a pile fabric that contains 0% or less of pile yarn, has a silky tone soft feeling, and hardly causes white blur.

[0002]

2. Description of the Related Art A pile fabric has standing hair on the surface of the fabric, has a unique appearance effect such as elegant luster and deep hue, and is used in many fields of clothing, interiors such as upholstery, and vehicle interiors. Widely used for materials. In particular, it is well known that a cut pile fabric made of a tricot knitted fabric is used for an automobile interior material, and polyester fibers are often used as a material of the pile fabric. With the development of the automobile industry, the quality required for pile fabrics is also gradually becoming higher and higher.

The most important characteristic of a pile fabric is that when weight is added to the pile fabric surface where a person sits or puts luggage, it is important that the pile returns to its original position when the heavy object is removed. Polyester fiber containing terephthalic acid as the main acid component and ethylene glycol as the main component,
The pile yarn easily falls in one direction or random direction,
There is a problem that the fall of the fiber is difficult to recover.

To prevent the pile yarn from falling easily and the fiber from hardly recovering, it is necessary to increase the thickness of the fiber. However, the texture becomes hard, and the feeling when seated becomes gritty and soft. I couldn't express the texture. In order to solve this problem, for example, Japanese Patent Application Laid-Open No. HEI 8-120542 discloses that the hardness of the texture of polyester fiber is adjusted not by crimping but by flat fiber A having a flatness of 2 to 6 and fineness of 2.5 to 5.
A pile fabric composed of a combination of fibers B having a denier of 3 and a degree of deformation of 3 or less is proposed. Polytrimethylene terephthalate fibers are also included in the polyester fibers, but as described in the specification, flat fibers are apt to fall down in the short axis direction, and a wide surface in the long axis direction faces the fabric surface, so that the reflected light It is strong and looks whitish (so-called white blur), giving a cheap impression. In particular, when there is no crimp, the tendency becomes remarkable.

In Japanese Patent Application Laid-Open No. Hei 5-5244, a non-crimped polyester fiber A and a crimped polyester fiber B are combined to improve silky soft texture and white blur due to pile collapse. JP-A-8-12
No. 0542 is the same in that two types of yarns are mixed, but in the case of Japanese Patent Application Laid-Open No. H5-5244, the production complexity due to the mixed use of two types of yarns, It is a cut of a mixed pile of crimped yarn that is easy to stretch due to external force and non-crimped yarn that is difficult to stretch, which is not enough to obtain a neat and uniform cut pile fabric, and there are local color spots due to bias of both fibers. , Was not enough for upgrading.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a pile fabric having a silky soft feeling and hardly causing white blur.

[0007]

Means for Solving the Problems As a result of diligent studies, the present inventors have found that at least 90% by weight of a specific crimp pitch and crimp elongation are piled with polyester fibers composed of polytrimethylene terephthalate. Has been found to be extremely effective, and has reached the present invention.

That is, the present invention comprises a pile yarn comprising at least 90% by weight of polytrimethylene terephthalate, the single yarn crimp pitch of which is 500 to 2000 μm, and the crimp elongation of 10% or less. Silky tone pile fabric. Hereinafter, the present invention will be described in detail. The polytrimethylene terephthalate used in the present invention is a polyester polymer containing terephthalic acid as a main acid component and trimethylene glycol as a main glycol component. Examples of the glycol include 1,3-propanediol and 1,2-propane. Although any of diol, 1,1-propanediol, 2,2-propanediol, and a mixture thereof may be used, 1,3-propanediol is particularly preferable in terms of elastic recovery, heat setting property, and thermal stability. .

[0009] In the polytrimethylene terephthalate fiber used in the present invention, in the range of 10% by weight or less,
Preferably, the content of isophthalic acid, succinic acid, or the like is within the range of 5% by weight, if necessary, within the range not impairing the effects of the present invention.
Even when an acid component such as adipic acid or 2,6-naphthalenedicarboxylic acid, a glycol component such as 1,4-butanediol or 1,6-hexanediol, ε-caprolactone, or 4-hydroxybenzoic acid is copolymerized. Good. However,
In this case, it is necessary that the amount of the copolymer component does not cause a decrease in the fastness. Further, if necessary, various additives, for example, matting agents, heat stabilizers, defoaming agents, tinting agents, flame retardants, antistatic aids, antioxidants, ultraviolet absorbers, infrared absorbers, A crystal nucleating agent, a fluorescent whitening agent and the like may be copolymerized or mixed as necessary.

[0010] The polytrimethylene terephthalate used in the present invention can be polymerized by a known method. For example, a transesterification reaction of terephthalic acid or a lower alcohol ester of terephthalic acid and an excess of 1,3-propanediol in the presence of a catalyst such as tetrabutyl titanate is performed, and then a catalyst such as tetrabutyl titanate is added to the obtained reaction product. In addition, the polymer can be obtained by performing a polycondensation reaction at 240 to 280 ° C. under a vacuum of 0.5 torr or less.

When copolymerization is carried out, a comonomer can be added at any stage of the above polymerization method. When copolymerizing a carboxylic acid represented by a sulfoisophthalate and a derivative thereof, it is preferable to add a comonomer at the beginning of the polymerization. The polytrimethylene terephthalate used in the present invention can be obtained by extruding from a spinneret, winding and then stretching.

[0012] The undrawn stretching method described here is a so-called ordinary method in which the yarn is wound around a bobbin or the like after spinning, and the yarn is stretched using another device. After being completely cooled and solidified, it is wrapped around the first roller rotating at a constant speed several times or more so that the tension before and after the roll is not transmitted at all,
It shows a so-called straight drawing method in which a spinning and a drawing and twisting steps are directly connected such that drawing is performed between a first roll and a second roll provided next to the first roll.

The spinning temperature at the time of melt spinning is 230 to 32.
0 ° C is preferred, and more preferably 235-300 ° C,
Particularly preferably, it is in the range of 240 to 280 ° C. If the spinning temperature is lower than 230 ° C., the temperature is too low, and it is difficult to obtain a stable molten state. On the other hand, when the spinning temperature exceeds 320 ° C., thermal decomposition becomes severe, and the obtained yarn is colored and does not show satisfactory strength and elongation.

The winding speed of the yarn is not particularly limited, but is usually preferably 3500 m / min or less, more preferably 2500 m / min or less, and particularly preferably 20 m / min or less.
00 m / min or less. Winding speed is 3500m / m
If it exceeds in, the crystallization proceeds too much before winding, and the stretching ratio cannot be increased in the stretching process, so that the molecules cannot be oriented, so that sufficient strength cannot be obtained or the tightness of the winding is reduced. Occurs, and the bobbin and the like cannot be removed from the winder. The stretching ratio during stretching is 2
It is preferably 4 times, more preferably 2.2 to 3.7.
Times, particularly preferably 2.5 to 3.5 times. If the stretching ratio is less than or equal to 2, the polymer cannot be sufficiently oriented by stretching, and the strength of the obtained yarn will be low. On the other hand, if it is four times or more, yarn breakage occurs frequently and stretching cannot be performed.

The temperature at the time of stretching is preferably from 40 ° C. to 80 ° C.
If the temperature of the drawing zone is lower than 40 ° C., yarn breakage occurs frequently during drawing, and it is not possible to obtain continuous yarn. 80 ℃
Exceeding the range worsens the slippage of the fiber with respect to a heating zone such as a drawing roll, so that the yarn breaks frequently and the yarn is full of fluff. Further, it is preferable to perform a heat treatment immediately after the stretching. This heat treatment is preferably performed at 90 to 200 ° C, more preferably 100 to 190 ° C, particularly preferably 11 to 11 ° C.
It is preferred to carry out at 0 to 190 ° C. Heat treatment temperature is 90 ° C
If it is less than 10, the crystallization of the fiber does not sufficiently occur, and the durability deteriorates. At a temperature higher than 200 ° C., the fibers are cut in the heat treatment zone and cannot be drawn. Further, even when the heat treatment temperature is 160 to 200 ° C., fluff and yarn breakage occur in a relaxed state.

The thus obtained polytrimethylene terephthalate used in the present invention is not particularly limited in physical properties, but has a strength of, for example, 2.5 to 4.5.
g / d, elongation 25-45%, elastic modulus 20-50g /
d, elastic recovery at 20% elongation 70-90%, melting point 22
A fiber having a temperature in the range of 0 to 240 ° C. and showing a soft texture is preferable.

The method for imparting crimp to polytrimethylene terephthalate fiber is, for example, a normal drawn yarn, a highly oriented undrawn yarn, so-called POY, or a spinning speed of 6000 m / m.
Minute or more, the usual twisting process is performed on the yarn wound, and the crimping is performed by stretching and setting the crimp in the heat setting zone after the false twisting, and the false twisting process at a low temperature and a low number of crimps. Is performed.

The temperature of the first false twist heater is 130 to 180.
° C, more preferably 140 to 170 ° C, particularly preferably 140 to 170 ° C, and 130 ° C.
If it is less than 1, the heat setting property is poor and the crimp becomes unstable.
When the temperature exceeds ℃, undesirably excessive crimping occurs. The temperature of the false twist second heater is preferably from 120 to 170C, more preferably from 130 to 160C. If the temperature is lower than 120 ° C., the heat setting property is poor and the crimp becomes unstable.
Exceeding the range is not preferred because crimping is excessive.

In the case of a thick pile fabric, it can be obtained by combining fibers. The method of plying yarn may be either twisting or drawing by a conventional method.However, if an appropriate interlacing treatment is applied, the fibers in the pile are extremely finely entangled, and the entanglement of the filaments is caused by a dyeing process. By making it more robust, the resistance to compression load is increased, and the effect of improving pile collapse aimed at by the present invention is enhanced. The number of confounds in the interlace processing is preferably in the range of 5 to 50 / m.

The crimped single yarn is measured at a single yarn crimp pitch L shown in FIG. Single yarn crimp pitch is 500 ~
2000 μm, preferably 500-180
0 μm. If it is less than 500 μm, the single yarns are strongly entangled with each other, resulting in a fabric having a rough texture that cannot be called standing hair. When the single yarn crimp pitch exceeds 2000 μm,
The pile is likely to collapse due to the load, and white blur is likely to occur, which is not preferable.

The crimp elongation is 10% or less, preferably 1 to
It is in the range of 10%, more preferably in the range of 2 to 8%, and if it is less than 1%, pile collapse due to load is likely to occur, which is not preferable. On the other hand, if the crimp elongation exceeds 10%, the pile surface has a felt touch, making it difficult to obtain a silky soft texture. That is, the pile in the felt tone loses the elegant luster and the deep hue, etc., which are the characteristics of the pile, resulting in a so-called white blur.
The collapsed pile is apt to be caught by fiber waste and the like, and becomes very dirty due to attachment of fiber waste and fine dust.

The fibers (middle yarn and back yarn) constituting the ground structure of the pile ground are not particularly limited in type, but it is generally preferable to use polyester fibers dyed in the same bath as the pile yarn. . In particular, it is preferable to use a polyester semi-dal yarn for the middle type. As the back yarn, it is preferable to use a high-shrink yarn such as semi-drawn or POY, and to increase the density by heat treatment.

In the pile fabric of the present invention, the basis weight can be changed depending on the length of the pile and the driving density. Usually 10
0g / m ² ~500g / m ² are preferred, more preferably 150g / m ² ~450m ^2, is less than 100 g / m ^2, the pile tends fall, heavier exceeds 500 g / m ^2, in the processing step Is difficult to handle, which is not preferable.

The pile fabric of the present invention is not particularly limited as long as the nap pile is constituted by a cut pile having a cut end. For example, pile fabrics such as velvet, moquette, bettin, and corduroy, double cut Russell center cut products, sinker pile knitted fabrics, cut pile fabrics by the tufting method, and pole tricots.

The pile fabric of the present invention can be used for interiors such as surface layers, chairs, sofas, curtains, etc. of seats on which heavy objects such as automobiles, trains, and aircraft are repeatedly applied.
It can be used in various applications such as clothing and bedding.

[0026]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail by way of examples. The main measured values in the examples were measured by the following methods. (1) Intrinsic viscosity [η] This is a value obtained based on the following definition formula.

[0027]

(Equation 1)

Ηr in the definition formula is a value obtained by dividing the viscosity at 35 ° C. of a diluted solution of the polyester polymer dissolved in o-chlorophenol having a purity of 98% or more by the viscosity of the solvent itself measured at the same temperature. It is defined as relative viscosity. C is the solute weight value in grams in 100 ml of the solution. (2) Single yarn crimping pitch After performing dry heat treatment at 180 ° C. for 5 minutes under no load, the crimping pitch (distance between peaks) of one single yarn was continuously 70 points in a tensionless state. Of all the filaments at a magnification of 80 times, and the average value is taken as the single yarn crimped pitch.

(3) Crimp Elongation Rate After performing moist heat treatment in a boiling state for 10 minutes without tension, a mark is made so that the interval becomes 20 cm correctly under an initial load of 2 mg / d. Next, the initial load was removed, a load of 0.1 g / d was applied, and after 30 seconds, the length between marks was measured and A (c
m). This measurement is performed ten times, and the average value of the values calculated by the following equation is defined as the crimp elongation.

Crimping extension rate = [(A-20) / 20] × 100 (%) (4) Pile Falling Property and Color Tone The pile cloth is placed horizontally with the pile surface facing up, and 80 g / cm is placed on the pile surface. A load was applied, the container was allowed to stand at 40 ° C. and 80% RH for 48 hours, and the pile inclination angle after deloading was measured. In addition, when the inclination angle of the pile is 70 degrees or less, the appearance and the color tone change can be clearly seen.

The appearance and color tone change after deweighting were evaluated and judged as follows. Grade 5: There is no change in color tone and there is a high-class feeling. Grade 4: Slight change in color tone. Grade 3: There is a change in color tone. Second grade: Color change is considerable. Grade 1: The color tone change is remarkable, and the sense of quality is impaired.

(5) A pile of black and white bokeh pile fabric is placed on an armchair with the pile face up, and the center line has an opening of 45 degrees and a V of 10 cm in width.
A load of 70 kg was applied to the letter-shaped plate, and after the load was removed, the degree of black spots and white blurs was observed from all directions, and judged as follows. ：: No black spots and no white blur.

Δ: Partially noticeable. X: considerably conspicuous. (6) Texture Softness and silk texture (silky tone),
It was determined whether or not there was a wool texture (wool tone, wooly tone).

[0034]

EXAMPLE 1 1121 parts by weight of 1,3-propanediol, 1300 parts by weight of dimethyl terephthalate (hereinafter abbreviated as DMT) and 1.3 parts by weight of titanium tetrabutoxide as a transesterification catalyst were used to prepare an ester at 220 ° C. An exchange reaction was performed. Next, 1.3 parts by weight of titanium tetrabutoxide was added as a polycondensation catalyst, and polycondensation was performed at 260 ° C. at a reduced pressure of 0.5 torr to obtain a fiber-forming polyester polymer. The intrinsic viscosity of the obtained polymer was 0.62.

The obtained polymer chip was heated at 130 ° C. for 10 minutes.
It was dried under a nitrogen stream of 0 ml / min for 20 hours. Next, at a spinning temperature of 290 ° C., using 36 single-array spinnerets,
An undrawn yarn was prepared by spinning at a spinning speed of 1200 m / min. Next, the obtained undrawn yarn is placed on a hot roll 50.
C., hot plate 140.degree. C., stretching ratio 3.0 times, drawing speed 600 m / min, and twisting, 75 denier / 3
A 6-filament drawn yarn was obtained.

Next, the number of false twists was 2300 using a two-heater false twister.
T / M and false twisting were performed under the conditions of a first heater of 150 ° C. and a second heater of 140 ° C. The single yarn crimp pitch of the obtained yarn was 650 μm, and the crimp elongation after boil treatment was 8.0% (hereinafter, referred to as A fiber). A
Two fibers are combined and interlaced, 38 pieces / m
And rewound as 150 denier / 72 filaments.

Next, a tricot machine having a special ball guide and two reeds was used.
A high-shrinkage polyester fiber of 36 filaments (boiling water shrinkage 20%, thermal stress peak stress 0.40 g / d)
The twined and interlaced yarn obtained above was supplied to the front reed. The swing motions of the back reed and the front reed were 10/12 and 01/10, respectively, and the pole guide made the same motion as the swing motion of the back reed.

The obtained knitted fabric is formed into a ground knitted fabric with the above-described high-shrinkage polyester fiber 75 denier / 36 filaments, and the knitted and interlaced yarn obtained above is combined with the ground knitted fabric and a pile loop. And a pile-shaped knitted fabric was formed. The pile tip of the pile loop of the pile-shaped knitted fabric was ciliad by a usual method to obtain a pile fabric having a pile length of 2.8 mm. Next, heat brushing was performed at 120 ° C., heat setting was performed at 170 ° C., dyeing was performed by a usual method, and then brushing was performed to obtain a cut pile fabric. The course density of the pile yarn of the cut pile fabric was 75 yarns / inch.

In the obtained pile fabric, the single yarn crimp pitch of the crimped polyester fiber was 920 μm, and the crimp elongation was 7%. Pile collapse property of the obtained pile fabric,
Black spots and white blur were evaluated. Table 1 shows the results.

[0040]

Comparative Example 1 915 parts by weight of ethylene glycol, DMT
A transesterification reaction was performed at 220 ° C. using 1300 parts by weight and 0.65 parts by weight of manganese acetate as a transesterification catalyst. Next, 0.65 parts by weight of antimony trioxide as a polycondensation catalyst and 0.39 parts by weight of trimethyl phosphite as a stabilizer were added, and the pressure was reduced at 285 ° C. under a pressure of 0.5 t.
Polycondensation was performed at orr to obtain a polymer.

The intrinsic viscosity of the obtained polymer was 0.65. 100 m at 130 ° C.
It was dried under a nitrogen stream of 1 / min for 20 hours. Then, at a spinning temperature of 290 ° C., spinning was performed at a spinning speed of 1200 m / min using 36 single-array spinnerets to prepare an undrawn yarn. Then, the obtained undrawn yarn is hot rolled at 50 ° C.
Stretching was performed at a hot plate temperature of 140 ° C., at a draw ratio of 3.0 and at a draw speed of 600 m / min to obtain a drawn yarn of 50 denier / 36 filaments.

Next, false twisting was performed using a two-heater false twister under the conditions of a false twist number of 2300 T / M, a false twist temperature of 170 ° C. for the first heater and 160 ° C. for the second heater. The single yarn crimp pitch of the obtained yarn was 540 μm, and the crimp elongation after boil treatment was 7.5% (hereinafter, referred to as B fiber). A pile fabric was obtained in the same manner as in Example 1 except that two B fibers were combined. Then heat brush at 140 ° C,
A cut pile fabric was obtained in the same manner as in Example 1 except that heat setting was performed at 190 ° C. The course density of the pile yarn of the cut pile fabric was 75 yarns / inch.

In the obtained pile fabric, the single yarn crimp pitch of the polyester fiber was 710 μm, and the crimp elongation was 7 mm.
%Met. The pile fabric obtained was evaluated for pile collapse, black spots, and white blur. Table 1 shows the results.

[0044]

Comparative Example 2 In the same manner as in Example 1, 75 denier / 3
A 6-filament drawn yarn was obtained. Next, the number of false twists was 4000 T / M with a two-heater false twister, and the false twist temperature was 1st heater 1
False twisting was performed under the conditions of 50 ° C. and a second heater of 140 ° C. The single yarn crimp pitch of the obtained yarn was 300 μm, and the crimp elongation rate after the boil treatment was 11.5% (hereinafter, referred to as “the crimp elongation”).
C fiber).

A cut pile fabric having a pile yarn course density of 75 / inch was obtained in the same manner as in Example 1 except that two C fibers were combined. In the obtained cut pile fabric, the single yarn crimp pitch of the polyester fiber was 420 μm, and the crimp elongation was 10.6%. The pile fabric obtained was evaluated for pile collapse, black spots, and white blur. Table 1 shows the results.

[0046]

Comparative Example 3 In the same manner as in Example 1, 75 denier / 3
A 6-filament drawn yarn was obtained. Next, the number of false twists was 900 T / M with a two-heater false twister and the false twist temperature was 15
False twisting was performed under the conditions of 0 ° C. and 140 ° C. of the second heater. The single yarn crimp pitch of the obtained yarn is 1500μ,
The crimp elongation rate after the boiling treatment was 4.1% (hereinafter, referred to as
D fiber).

A cut pile fabric having a pile yarn course density of 75 yarns / inch was obtained in the same manner as in Example 1 except that two D fibers were combined. In the obtained pile fabric, the single yarn crimp pitch of the polyester fiber was 2100 μm, and the crimp elongation was 3%. The pile fabric obtained was evaluated for pile collapse, black spots, and white blur. Table 1 shows the results.

[0048]

[Table 1]

[0049]

Industrial Applicability The pile fabric of the present invention eliminates the disadvantage of pile collapse, which has been a factor that hinders the luxury of conventional pile fabrics, and has a high-grade, silky soft texture and commercial value. Very high pile fabric suitable for interior decoration.

[Brief description of the drawings]

FIG. 1 is an explanatory view schematically showing a crimp mode and a crimp pitch L of one single yarn after dry heat drawing.

Claims (1)

[Claims] 1. A silky tone pile fabric comprising at least 90% by weight of polytrimethylene terephthalate, a single yarn crimp pitch of 500 to 2000 μm, and a pile yarn having a crimp elongation of 10% or less. .