JPS61102461A - Carpet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a nylon carpet with less sag and a good feel.

[Conventional technology]

Conventionally, the required characteristics of carpets are that they have little sag and have a good texture. As a reminder, the material for carpets is nylon.

Polyester, acrylic/L/, Oop, etc. are used, but nylon is widely used because it is inexpensive and has relatively good physical properties.

Among nylons, nylon 6 and nylon 66 are currently available.

As a conventional technique, 1, for example, as shown in Japanese Patent Publication No. 59-20024, nylon 6-ply twisted yarn T-12
After heat setting with steam heat at a temperature higher than 0℃.

A carpet 1 is formed using the combined twisted yarn as pile yarn.

There is a technique of dyeing and then treating with a cationic surfactant. It is true that this technology improves heat setting properties,
Although the sag was reduced, because the material was nylon 6, it had poor heat resistance, so it was not possible to achieve a sufficient improvement in the sag. Even if temporary fibers were processed at high temperatures and their settiness was improved, other important properties, such as texture, were hardened and yarn strength was extremely low, making the product unsuitable for practical use. .

Nylon 66″f: When used as a material, υ is smaller than nylon 6, but it has not yet reached a sufficient level.

Taking these circumstances into consideration, the present inventors have proposed to use polytetramethylene adipamide fibers (nylon 4,6 fibers), which have a higher melting point and a higher crystallization rate than nylon 6 and nylon 66, for carpet materials. Please pay attention to.

Nylon 4,6 polymer has been used as an industrial product for plastic molding for a long time (for example, Japanese Patent Application Laid-Open No. 149429-1983).
There is also an example of a method for manufacturing tire cord yarn as a fiber for industrial materials (for example, Japanese Patent Application Laid-Open No. 59-88911), but it has not been put to practical use or proposed for use in interior goods or carpets.

[Problem that the invention seeks to solve]

We have improved Dt to a practically sufficient level that could never be achieved with conventional nylon 6 and nylon 66 materials,
At the same time, it is intended to provide the soft texture unique to nylon.

[Means for Solving the Problems] The present invention provides that at least 30% by weight of the p-ply yarn or cut pile yarn constituting the surface of the carpet is composed of tetramethylene azide in which 80 mo/l/% or more of the repeating units are It is a carpet made of curled yarn of fibers with pamid bonds. Here, the carpet includes indoor carpets and mats such as car mats, entrance mats, and kitchen mats.

In general, to improve the stiffness of a carpet, it is sufficient to improve the stiffness of the carpet's loop yarns, and the most effective means for achieving this is to perform strong heat fixation through high-temperature shrinking processing. In order to have the soft feel of a nylon material, it is preferable to use a material that has a load/elongation curve similar to that of nylon 6 or nylon 66.

Based on the above-mentioned idea, the inventors of the present invention conducted extensive studies and found that polytetramethylene adipamide is the most suitable material.

The reason why polytetramethylene adipamide is most suitable is that, as mentioned above, polytetramethylene adipamide has a higher melting point than nylon 6 and nylon 66, and has a high crystallization rate. Because it can be compressed and heat-set (for example, by using a stuffer box to shrink it), there is less shrinkage, and it is very effective for carpets that have been tufted into piles or cut piles. It becomes stable with less shrinkage.

Further, the crimped yarn having a high melting point has a favorable effect on tufting processability.

Also, polytetramethylene adipamide fiber.

Since it is similar to nylon 6 and nylon 66 and has a 7'C load/elongation curve, it can have a soft feel like conventional nylon.

Violet fibers made of polytetramethylene adipamide fibers are characterized by higher heat resistance and lower heat shrinkage than nylon 6 and nylon 66. This is very advantageous in terms of tuftability and uniformity of tufted pile length.

Second, it is necessary that at least 30% by weight of the pile yarn or cut pile yarn of the carpet of the present invention be polytetramethylene adipamide fiber.

Although it depends on the characteristics of the carpet, such as the unique color effect due to mixed fibers, the preferred composition of the polytetramethylene adipamide fibers is 30% by weight or more, more preferably 50% by weight.
The above is necessary.

This is because if the proportion of the crimped fibers of the polytetramethylene adipamide fibers is less than 30 wt.ffi% of the total pile or cut pile constituent yarns, the effect of improving the setness is not substantially observed. Further, it is necessary that the fiber has 80 or more repeating units composed of tetramethylene adipamide bonds. If the repeating unit is less than 80 mo/l/%, the melting point of the fiber will decrease.

Therefore, heat fixation at high temperatures becomes difficult, and the effect of improving stiffness is reduced.

Fibers other than polytetramethylene adipamide fibers include other thermoplastic synthetic fiber yarns (for example, nylon 6, nylon 66, polyester/L/, acrylic, etc.), or yarns mixed with natural fiber yarns such as wool and rope. Alternatively, it may be a blended yarn, or a plied yarn.

Next, a brief description will be given of the present invention (f), a method for producing curled fibers of polytetramethylene adipamide fibers having grooves, but the present invention is not limited to the method described below.

The main ingredients are tetramethylene diamine and 7-divind chips at a higher temperature than usual, ie.

Melt spinning at 290-310°C. In this case, it is necessary.
Antioxidants, light stabilizers, matting agents, flame retardants.

A modified polytetramethylene adipamide fiber may be obtained by blending one or more types of anti-fouling agents.

9. Irregular cross-section threads (e.g. triangular cross-section, square cross-section.

It is preferable to use a fiber yarn with a hollow cross section because it has excellent elasticity and antifouling properties, but a fiber yarn with a round cross section may also be used.

Next, the obtained undrawn yarn is wound up continuously or in one stretch, stretched, and then crimped.

The shrinking process can be carried out using various types of shrinking machines generally used for thermoplastic synthetics and fibers, such as air stuffer type, stuffer type, gear type, false twist type, and knit-denit type. The processing conditions can be the same as those for nylon 6 and nylon 66, but in order to fully exhibit the effects of the present invention, the heat set temperature for crimping should be higher than that for nylon 6 and nylon 66. For example, in the shrinking process of Air Stuff 8A type, a stuffing temperature of 220°C to 320°C is preferred.

The crimped yarn thus obtained is used as a loop yarn and subjected to tufting and finishing in the same manner as in the usual carpet manufacturing process to make a carpet.

In this case, the first base fabric may be made of the same yarn as the pile yarn, or may be a base fabric that is normally used for carpets. For example, polypropylene fabric.

Polypropylene nonwoven fabric, polyester spunpond, etc. Further, the denier of the yarn, the number of filaments, the number of yarns to be folded, the basis weight, the tufting conditions, the dyeing conditions, the backing treatment conditions, etc. may be the conditions normally used for carpets.

The above is a polytetramethylene adipamide fiber Ken shrink yarn (
Although the method for producing a carpet using BCF) t-/L/- loop yarns has been briefly described, it is also possible to use spun yarns as loop yarns. In this case, a product with good texture can be obtained by blending or blending wool fibers, Ml fibers, or other synthetic fibers with polytetramethylene adipamide fibers.

Also, the carpet has a high/low loop.

Level loop, cut-by A/, jaggy, and saxony are also good.

〔Example〕

The present invention will be explained below with reference to Examples, but the present invention is not limited to these Examples.

Example 1 Polytetramethylene adipamide polymer chips (relative viscosity: 3.0, melting point: 290°C) were dried at 100°C under reduced pressure for 24 hours, and then subjected to melt spinning-stretching-Ken M processing (air stuffer type). ) 7fr of Ken Crinkled Fiber (BCF) of 800 denier 64 filament yarn with a triangular irregular cross section of 2.5 was obtained using a 41-ill apparatus. In addition, the shrinking processing conditions at this time are as follows.

Stuffing temperature 270℃, air field 6 kg/c
This was done at tA.

This yarn is given a first twist of 110T/M (Z twist).

Three of these yarns are twisted together, 90T/M (S twist) is applied to make a loop yarn, and a polypropylene fabric (22 yarns/inch in the warp, 14 yarns/inch in the width) is arranged as the base fabric for a loop bail. Tufting Mann (1/10"G) 8 stitches/inch, pie/'L/height 7jfjl.

After tufting under the condition of a pile weight of 600t/d, dyeing (wince type at 98℃, 60 minutes), drying, and backing (latex coating 1.5 kp/n?).

After finishing, a level loop pile carpet was obtained.

The total sag of the carpet product was measured by the rate of thickness reduction due to dynamic loading using the tJIs LIQ21 method.

Regarding the texture, 100 people also conducted a sensory evaluation of Ishu Rei ÷, and those who answered that 90 Å or more is good were 70, 7.
Those for which 0 to 90 people answered that it is good and those that answered that 0°10 Å or less is good are expressed as Δ.

The results are shown in Table 1.

Comparative Example 1 Nylon 6 polymer chip (relative viscosity: 3.0, melting point:
Level/L of nylon 6 fiber yarn obtained by the same manufacturing method as the poly 4 tetofumethylene adipamide polymer described above, except that the shrinking process was performed at a stuffing temperature of 210°C (226°C). A //L/-pile carpet was made, and the settling and texture were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

Table 1 As is clear from Table 1, the car head made of polytetramethylene adipamide of Example 1 of the present invention had the following properties:
Compared to Comparative Example 1, a conventional carpet made of nylon 6, the carpet had much less sag, had a good texture, was highly elastic, and was smooth. On the other hand, Comparative Example 1 had a slightly slimy feel.Example 2 The same polytetramethylene adipamide as in Example 1 and the same nylon 6 as in Comparative Example 1 were used as raw materials, and after drying, the former was 310°C, and the latter was melt-spun at a spinning temperature of 275°C to obtain triangular irregular cross-section yarns 6 with a degree of irregularity of 2.5.
An undrawn yarn of 720 denier and 40 filaments was wound.

The undrawn yarns were combined to have a denier of 100 denier, and then stretched, pressed, crimped, and knee-cut in succession, resulting in 13 crimps. Crimp degree 22.15 denier 13111x
A parikat curdled staff/L/@fiber was obtained.

In addition, the hot plate temperature in the indentation shrinking process was 260°C for polytetramethylene adipamide and 220°C for nylon 6.Next, the obtained staple fibers were dyed with gold Obermeyer, washed, softened, After drying, polytetramethylene adipamide fiber and nylon 6 staple P fiber were blended at the mixing ratio shown in Table 2 to obtain 1/6g'
Z 150 T /rp#) semi-worsted spun yarn was obtained. This spun yarn was used as a pile yarn, and the same fabric as in Example 1 was arranged as the base fabric for tufting (1/10//G, 12 stitches/inch, pie/L/Ryo 1~°1, 8wl, 11 piles). Fabric weight: 6701/ld), then metting (latex application 1.5'y*, shirring pufferfish 2 connections), cut pile type carpet A.

B, C, D, E, F, Gt-obtained.

The carpet was evaluated for wear and feel in the same manner as in Example 1. Table 2 shows the results.

As is clear from Table 2, the carpet of the present invention is A,
E, F, and G have less settling and a good texture.

Table 2 [Effects of the Invention] The nylon carpet of the present invention has very little wear and has a good texture.

Claims (1)

[Claims] A carpet characterized in that at least 30% by weight or more of the loop pile yarns or cut pile yarns constituting the surface of the carpet are made of crimped yarns of fibers in which 80 mol% or more of the repeating units are composed of tetramethylene adipamide bonds. .