JPH08199437A - Long and short composite carpet yarn and carpet with little play hair - Google Patents

Abstract

(57) [Abstract] [Purpose] The generation of idle hair is suppressed, the unique texture and appearance of spun yarn are maximized, and the durability (compression) of the three-dimensional random crimped filament fiber (BCF) is provided. (Provided that the retention rate) is also provided, and further, the texture is good without using the low melting point fiber, and not only the loop pile carpet but also the velor tone,
Providing a wide range of carpets with little play hair, from plush to saxony to shaggy. [Structure] The thickness displayed in metric count (Nm) is 2N
In a carpet yarn of m to 10 Nm (900 to 4,500 denier), the carpet yarn includes staple fibers 20 to 20 having an average cut length of 75 to 250 mm.
A long and short composite carpet yarn mainly composed of 90% by weight and 80 to 10% by weight of three-dimensional randomly crimped long fiber filaments, and a carpet with little idle hair using the same.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a long and short composite carpet yarn and a carpet having less play hair, and more specifically to a carpet in which monofilaments suspended in pile yarn, so-called "play hair", hardly occur. The present invention relates to a long and short composite carpet yarn capable of providing and a carpet with less play hair using the same. Here, the long / short composite carpet yarn is a yarn for carpet in which at least one kind of three-dimensional random crimped long fiber filament and at least one kind of staple fiber are combined.

[0002]

2. Description of the Related Art A carpet composed of spun yarn made of staple fibers has so-called "play hair" that appears on the surface of a carpet on which monofilaments suspended in pile yarn are laid. Therefore, the current situation is that it is used while allowing this. This is because the carpet using spun yarn has fluff as compared to the carpet made of three-dimensional random crimped filament fiber (BCF) that does not produce idle hair, and therefore has a soft touch and is highly bulky. In addition, various cottons can be mixed, and various textures can be expressed, which is an advantage.
However, the occurrence of play hair as described above cannot be avoided, and the range of use is limited.

That is, in a carpet using spun yarn, in a room in which precision equipment is installed, a room in which an air conditioner is installed, or the inside of an automobile, cotton dust caused by idle hair adversely affects instruments. Sometimes. In view of the above problems, nothing has been found to be satisfactory, and the problem of idle hair is accepted as being unique to carpets using spun yarn.

By the way, polyester fibers have a higher Young's modulus than other fibers, and carpets made of these fibers tend to have a hard texture. Also, in order to obtain bulkiness, if you make a tri-lobal cross section, a hollow cross section, etc.,
The texture becomes even harder. As measures against these problems, proposals have been made to make single fiber denier thin, to make the cross section flat, and to devise the crimped shape. However,
Thinning the monofilament denier increases the number of monofilaments that make up the spun yarn, thus increasing the number of fluffs per unit length of the spun yarn, and increasing the number of idle hairs.

Heretofore, as a method of reducing idle hair, a method of mixing low melting point fibers in spun yarn has been generally proposed. For example, in Japanese Patent Laid-Open No. 62-117869, an ordinary short fiber (staple fiber) made of polyester, polyamide, polyacrylonitrile or the like having a cut length of about 152 mm has a cut length of about 51 mm having a melting point lower than that of the short fiber. The spun yarn obtained by mixing and spinning the low melting point staple fibers is heat-treated to melt-bond the low melting point fibers, and the tufting is performed to form a cut pile and / or a loop pile. Carpets that are solid and have a sharp pencil point have been proposed. However, in this carpet, since the low-melting-point fibers are melted, the texture becomes coarse and hard, and although the occurrence of idle hair is suppressed, the characteristics such as polyester fibers are significantly impaired from the textured surface.

Japanese Utility Model Publication No. 6-23591 discloses that
(A) Low shrinkage fiber with a cut length of about 127 mm, (b) High shrinkage with a cut length of about 102 mm, and cut length 1
(C) A low melting point fiber (c) having a diameter of about 02 mm, and tufted on a base fabric with spun yarn that defines the ratio of each fiber and denier of single fiber, backing the latex, and then heat-treating it under latex drying temperature conditions. A carpet with little play hair is proposed. However, this carpet is intended to prevent rough texture hardening due to melting of the low melting point fiber, the manufacturing process thereof is complicated, and since the low melting point fiber is used, it is not advantageous in terms of cost.

Further, in Japanese Unexamined Patent Publication (Kokai) No. 52-66750, a spun yarn (single yarn) is obtained from a hollow fiber having a cut length of 89 mm with a twist coefficient (α) of 60 to 120, and two spun yarns are obtained. It is described that idle hair is prevented by applying the upper twist of 55 to 110% of the lower twist. However, with this method, since the cut length is short, it is not possible to actually prevent play hair.

[0008] Furthermore, carpets using spun yarns generally have many carpet styles in which twists such as plush and saxony are fixed, and velor-like carpets with few twists that have a good appearance and quality have been proposed so far. It has not been.

On the other hand, the carpet made of the three-dimensional random crimped filament fiber (BCF) as described above is
There is almost no play hair due to the use of long fibers. However, compared to using spun yarn, soft touch and bulkiness are poor, and it is difficult to mix various long fibers,
It has the drawback that it is impossible to express a variety of textures.

Further, the wrap yarn of the innovative spinning is obtained by winding the spun staple fiber bundle around the filament yarn and converging it, and the filament yarn is used for winding, and the staple yarn is also used. The mixing ratio with respect to the fiber is low, and is 10% by weight or less at most. Moreover, the filament yarn used here is a flat yarn, and the use of this wrap yarn as a carpet yarn is not disclosed at all.

[0011]

DISCLOSURE OF THE INVENTION The present invention has a carpet yarn, which suppresses the occurrence of idle hair, maximizes the unique texture and appearance of spun yarn, and has a long-fiber bulked crimped yarn. Providing a carpet that can also exhibit durability (compression retention rate), good texture without using low melting point fibers, and loop pile carpet, velor tone, plush tone, saxony, It is an object of the present invention to provide a long and short composite carpet yarn capable of obtaining a carpet having little play hair over a wide range from shaggy.

[0012]

According to the present invention, the thickness expressed in metric count (Nm) is 2 Nm to 10 Nm (900 to
4,500 denier) carpet yarn having an average cut length of 75 to 250 mm.
Staple fiber (hereinafter also referred to as "SF") 20
The long-short composite carpet yarn is mainly composed of ˜90% by weight and 80 to 10% by weight of a three-dimensional random crimped long fiber filament (hereinafter also referred to as “BCF”).

Here, the form of the carpet yarn of the present invention is such that three-dimensional randomly crimped filament filaments are arranged inside the yarn, and staple fibers are positioned around the filaments so that the filaments are wrapped around the filaments, and the wrapping interface between the two. Then, it is preferable that at least a part of the staple fibers is integrated while being inserted into the three-dimensional randomly crimped filament fiber.

The carpet yarn of the present invention has a fluff coefficient (K) defined by the following general formula (I) of 10 to 15.
It is preferably 0 (ends / cm). Fluff coefficient (K) = {[(De / de) / L] × 2} × R ... (I) [In the above general formula (I), De is the total denier of the carpet yarn and corresponds to the above metric number. 900 to 4,50
0 denier, de is the average single fiber denier of the staple fiber 3 to 20 denier, L is the average cut length of the staple fiber, and here, for convenience, the unit of "cm" is adopted, and the value is 7.5 to 25 cm, R is a mixing ratio of staple fibers in the carpet yarn and is a numerical value of less than 1. ]

Next, the present invention provides a loop pile carpet having less play hair, which is obtained by tufting the above-mentioned long and short composite carpet yarn with a basis weight of 250 to 1,000 g / m ² and a loop pile length of 3 to 10 mm. is there.

The present invention also provides the above long and short composite carpet yarn with a basis weight of 250 to 900 g / m ^{2 and} a weight of 3 to 3.
It is a velor-like carpet tufted with a cut pile length of 10 mm and having little idle hair.

Further, according to the present invention, the above-mentioned long and short composite carpet yarn is twisted with a twisting coefficient (α) of 40 to 120, and the yarn having a basis weight of 400 to 1,000 g / m ² and 3 to 3 is used.
A plush-like carpet tufted with a cut pile length of 10 mm and having little idle hair.

Finally, in the present invention, the above long and short composite carpet yarn is pretwisted with a twisting coefficient (α) of 40 to 140, and then a plurality of the pretwisted 55 to 110 of the pretwisted are prepared.
% Twisted in the number of twists of 600% to 1,500 g
It is a saxony carpet with a unit weight of / m ² and tufted in a cut pile length of 5 to 20 mm with little play hair.

In the present invention, the average cut length is 75 to 250.
mm SF20-90% by weight, and BCF80-10
The thickness represented by the metric number Nm is 2 Nm (4,500 denier) to 10 Nm, which is mainly composed of weight%.
A long and short composite yarn having a thickness of (900 denier) is preferably subjected to sweet twisting, and further twisting and plying if necessary, and heat setting in some cases to obtain a carpet yarn.
Here, the metric number (Nm) is defined by the following general formula. Meter count (Nm) = 9000 / De (In the above general formula, De is the same as above and SF and BC
Figure 9 shows the total denier of a carpet yarn made of F. )

The spun yarn is an aggregate of SF and has an infinite number of fluffs in the length direction. When observing a carpet yarn having a certain thickness, the number of fluffs becomes smaller as the constituent monofilament denier is thinner. Will increase. FIG. 2 is a diagram schematically showing a side surface when a carpet yarn made of spun yarn is tufted as a cut pile on a base fabric. In the case of loop pile, the pile tips (shown by broken lines) are connected, but in the case of cut pile, each pile yarn is independent when it is planted in the base cloth, and the root portion Are secured by backing agents so that each pile does not come off.

FIG. 3 is a model diagram showing how individual single fibers constituting a carpet yarn made of spun yarn exist in a tufted pile. In FIG. 3, in the case of (A), 1 is applied over the entire length of one pile.
(B) to (C) are cases where the monofilament ends in the middle of the pile, (D) is cases where the monofilament is composed of only one end of the pile, (E) )
Is a case where the monofilaments that make up the pile are suspended,
(F) shows cases where some of the single fibers in the pile are cut for some reason.

Generally, the idle hair generated on the carpet is
There are many cases that arise from the states of (E) and (F) in FIG. Of these, (E) should be removed by the carpet manufacturing process, and (F) depends on the strength of the material selected. In addition, even in the states of (A) to (D), play hair is naturally generated if the fixation of the pile by the backing is incomplete.

The inventors of the present invention have described "JI" for various carpets on which the degree of occurrence of play hair is completely backed.
SL 1023 Reference 4 ”
z) Various studies were conducted in the test. Here, the pile fluff removal rate is a value obtained by dividing the falling weight of the pile after rubbing for 30 minutes with a load of the friction element of 8 kgf (78.4 N) by the pile weight of the friction surface and is represented by the following formula. Pile fluff hair loss rate = (hair loss after fuzz test / pile weight before fuzz test) x 100 (%)

Table 1 uses various carpet yarns,
Fuzz test [8kgf (78.4N) of saxony tone cut carpet tufted with tuft standard 1/8 gauge (G), pile length 10mm, and basis weight 1,000g / cm ^2.
× 30 minutes] data.

[0025]

[Table 1]

*) Fuzz appearance: Grade 5 (no surface change at all) to grade 1 are evaluated, with grade 5 being the best grade. As is clear from Table 1, the pile fluff loss rate is 0 for nylon BCF carpets (carpets using nylon three-dimensional random crimped long fiber filaments), whereas the carpets using spun yarn have strong abrasion resistance. Except for nylon SF carpet (carpet using spun yarn composed of nylon SF), the value is around 3%, and for wool, it reaches 5% or more. Polyester SF carpet (carpet using spun yarn composed of polyester SF) has a pile fluff removal rate of about 2.9% and a fuzz appearance of about 2.5 grade, and acrylic SF carpet (spun from acrylic SF. Carpet using yarn) is at a similar level.

The present inventors, based on such knowledge,
The use of spun yarn was investigated to obtain a carpet yarn and carpet with less play hair. Here, as a method of suppressing the occurrence of idle hair, for example, it is conceivable to increase the number of twists to bundle the spun yarn or to reduce the pile height of the carpet. However, the former method is not preferable because the yarn bulkiness is negative, and the latter method limits the pile height of the carpet.

On the other hand, the present inventors have paid attention to the cut length of SF, which has a completely different concept from the above method,
As a result of examining a carpet using spun yarn, an unexpected fact was found. Figure 4 shows a metric count (Nm) of 3.0
No. (3,000 denier) SF (triangular cross-section shape) constituting the polyester spun yarn [twisting coefficient (α) = 52]
Cut pile carpet when changing the cut length of monofilament denier 6 de or 8 de (tuft standard = 1/1)
It is a graph which shows the pile height of 0G, 7.6 stitches / inch), and the pile fluff deficit rate defined above.

As is apparent from FIG. 4, when the cut length of SF constituting the spun yarn is constant, the idle hair (pile fluff loss rate) tends to increase as the carpet pile height increases. By increasing the cut length,
Pile fluff hair loss rate decreases sharply. Pile height is 4
In the case of about 10 mm, the pile fluff removal rate is 2 for the spun yarn with a cut length of 150 mm or less that has been used so far.
It is about 3%. On the other hand, the cut length is 150 mm
At 192 mm, the pile fluff loss rate was 1.0% or less, even if the pile height of the carpet was 9.0 mm.
Almost no play hair is observed.

The present invention has been made on the basis of such knowledge, and the concept thereof is "fluff coefficient (K)" of spun yarn.
And "effective fluff number (EK)" on the carpet. Here, the fluff coefficient (K) of the spun yarn
Is a numerical value represented by the following formula, and when SFs constituting a spun yarn of a certain thickness are arranged at equal intervals, one single fiber has two fluffs (yarn ends), It is a measure of the number of fluffs per length. In this equation,
The shrinkage due to SF crimping is not taken into consideration, and a numerical value called the cut length of raw cotton is usually used. Fuzz factor (K) = [(spun yarn De / single fiber de) / cut length] × 2 (ends / cm) [wherein, spun yarn De is the total denier (de) of spun yarn, and monofilament de is spun yarn. SF single fiber denier (d
e), the cut length is the average cut length (cm) of the SF constituting the spun yarn. ]

The effective number of fluffs (EK) is a numerical value showing the total number of fluffs in a fixed volume of the carpet pile.
It is expressed by the following formula. Number of effective fluffs (EK) = [(number of gauge needles) (number of stitches)
(Pile height) x 2 x K] / (2.54 x 2.54)
(Ends / cm ² ) [In the formula, the number of gauge needles is the density of the tufting machine (pieces / inch), the stitch is the number of piles driven (pieces / inch), the pile height is cm, and K is the fluff coefficient. . ]

FIG. 1 shows the relationship between the length of SF (average cut length) and the fluff coefficient (K) constituting a spun yarn for a spun yarn of metric count (Nm) No. 3 (3,000 de). The single-hatched area is a preferred area of the present invention. That is, the area of single hatching is an area for the purpose of the texture effect due to the fluff of SF and the prevention of play hair, and the area of double hatching is a particularly preferable range. The meaning of the area of the present invention is, for example, a conventional single fiber denier of 10 de and an average cut length of 100.
Instead of the spun yarn of mm, a spun yarn of single fiber denier of 5 de and an average cut length of 200 mm can produce carpet of the same standard while maintaining the fluff coefficient (K) at the same level. It is to suppress the generation of hair and to soften the texture of the carpet.

Further, in FIG. 5, the metric number (Nm) is 3
No. (3,000 de) spun yarn (SF single fiber denier = 5 de, 8 de), the average cut length of SF was changed [different fluff coefficient (K)] spun yarn effective carpet fuzz (EK) And the change in pile fluff hair loss rate or fuzz appearance. Pile fluff hair loss rate (amount of play hair) in proportion to the number of effective fluffs (EK).
Changes. Effective fluff number (EK) 1,500 (ends
/ Cm ² ) or less, pile fuzz loss rate is 2.0
There is a particularly remarkable effect that it can be kept below%. Further, it can be seen that the fuzz appearance is also improved and a carpet with less play hair can be obtained.

According to the present invention, these findings, that is, increasing the average cut length of spun yarns, reduces the pile fluff loss rate and fluff coefficient (K) in carpets (FIGS. 1 and 4), and the effective fluff. If the number (EK) is small, the pile fluff hair removal rate will be low (Fig. 5). Furthermore, if BCF is mixed in this spun yarn, the spun yarn can be made thinner by the amount of BCF. This is based on the finding that the number of fluffs can be reduced and a carpet with less idle hair can be obtained.

That is, it is understood that the fluff coefficient (K) defined by the general formula (I) can change the number of fluffs depending on the mixing ratio (R) of the spun yarn (carpet yarn). The BCF mixed in the spun yarn must be a continuous filament fiber having a three-dimensional random crimp. In the case of a straight filament to which random crimps are not applied, only the filaments are bundled, and it is difficult for them to adapt to SF, and it is difficult to integrate them into 1. With BCF, the entire randomly crimped filament is easily opened. Therefore, if the SF spun in the spinning process is mixed with BCF immediately before being wound up on the spinning machine, the SF becomes a long / short composite yarn integrated with the BCF in an opened state. That is, the long / short composite carpet yarn of the present invention is such that, even when piled into a carpet when it is made into a carpet, the BCF is positioned inside (relatively the core portion) and SF is wound around the BCF, and both are wound. SF is partially BC at the attached interface
It is possible to form a well-formed pile, even though it is a core-sheath type because it is integrated while penetrating into F.

As the form of the long and short composite carpet yarn of the present invention, in addition, a form in which BCF and SF are intertwisted in the above spinning process, and a form in which BCF and SF are entangled by fluid processing, It is also possible to take a form in which SF is bundled around the BCF.

In the carpet yarn of the present invention, SF
A method in which spun yarn is manufactured from the above and then twisted with BCF or woven at the time of tufting is not preferable because each carpet pile exhibits its own behavior. Therefore, as described above, it is preferable that SF is spun out in the spinning step and BCF is mixed therein before being twisted in the spinning machine to form a long-short composite yarn.

FIG. 6 shows polyester SF and nylon BC.
7 is a graph showing the relationship between the SF ratio and the pile fluff loss rate in a composite yarn with F. According to FIG. 6, B
The higher the amount of CF, the lower the hair loss rate of piles,
That is, it can be seen that the amount of play hair generated is reduced.

As described above, the present invention is a carpet yarn in which SF and BCF are integrated, and the nature of the carpet yarn is greatly influenced by the type of BCF mixed. In particular, when the BCF is nylon, the durability of the resulting carpet yarn is significantly improved, and a carpet having high compression durability can be obtained. By the way, we used the Tetrapot Walker Test (TPW
The compression retention rate of the T) method was evaluated.

Here, in the TPWT method, a pile is mounted face up on the inside of a drum having a diameter of 20 cmφ rotating at 80 rpm, and a tetrapod of four legs [weight 1.3 kgf
(12.7N)] into the drum, and the drum is 9,60
Rotate at 0 rpm to dent the carpet, compressing energy of the carpet before and after the test [2.0 kgf / cm
² ) (compressibility retention rate) is measured from the rate of change in energy required for compression to ² (0.196 N / mm ² ). According to this TPWT method, polyester SF10
Carpet of 0% and acrylic SF100% has a compression retention of 55-60% and nylon BCF100% of 85-85.
90%. Therefore, the mixture of SF and BCF has a compression retention rate of 65 to 7 depending on the mixture rate.
It can be seen that it is improved to 0%.

The carpet yarn of the present invention is mainly composed of SF having a thickness of 2 Nm to 10 Nm and an average cut length of 75 to 250 mm, which is indicated by a metric count.
At that time, the single fiber denier of SF is in the range of 3 to 20 de.

Generally, the polyester spun yarn for carpet has a thickness of 10 Nm expressed in metric count (Nm).
(900 denier) to 2 Nm (4,500 denier),
Preferably 3 Nm (3,000 denier) to 7.5 Nm
(1,200 denier) is used. 10 Nm
If it exceeds, it is too thin and unsuitable for carpet, while if it is less than 2 Nm, it is too thick and the quality of the carpet is impaired.

The SF used in the present invention has an average cut length of 75 to 250 mm, preferably 100 to 230 mm. When it is less than 75 mm, the amount of play hair generated increases, while when it exceeds 250 mm, the number of fluff becomes excessively small, and S
In some cases, the texture effect due to the fluff of F disappears, and the bulkiness of the carpet yarn as a whole also disappears, making spinning impossible. In addition, SF single fiber denier is 3 to 2
It is 0 de, preferably 4 to 15 de. When it is less than 3 de, when it is used as a carpet, the texture is too soft and inferior in durability, while when it exceeds 20 de, the texture becomes coarse and hard,
The quality is impaired.

Here, SF means crimped short fiber,
For example, synthetic fibers such as polyester fibers, polyacrylonitrile fibers, polypropylene fibers, etc., which are crimped by gear crimping, indentation crimping, etc., and then cut to a predetermined cut length with a gurgle cutter, a Marston cutter, etc. Is. This SF is 2 in advance.
Three-dimensional three-dimensional crimps can be expressed by relaxation heat treatment or the like by subjecting the polymers belonging to the same species to side-by-side composite spinning or asymmetrically heating and / or cooling the spun yarn. The latent three-dimensional crimpable fiber may be used. The SF has crimps to the extent that it can be spun, and the crimping form is not particularly limited, such as a zigzag crimp in a push shape and a three-dimensional random crimp. Further, the cross-sectional shape of the monofilament that constitutes the SF may be any shape such as a round cross section, a triangular cross section, a Y cross section, or a cross section, or the cross section may have a hollow portion inside.

The average cut length of SF or the average single fiber denier is the average length of the fiber length of SF forming the spun yarn or the average denier of single fibers. In SF, the cut length or single fiber denier becomes the average cut length and average single fiber denier as they are. However, when a plurality of (n types) SFs having different cut lengths or single fiber denier are used, the average cut length or average single fiber denier is calculated by the following formula. Average cut length (L) = [D (a ₁ l ₁ / d ₁ + a ₂ l ₂
/ D ₂ + ... a _i l _i / d _i + ... a _n l _n /
d _n )] / [D (a ₁ / d ₁ + a ₂ / d ₂ + ... a _i
/ D _i + ... a _n / d _n )] Average single fiber denier (de) = a ₁ d ₁ + a ₂ d ₂ +
.. a _i d _i + ... a _n d _n L; average cut length (mm) of SF constituting spun yarn D; thickness of spun yarn (denier) a _i ; i-th (kind) SF Mixing ratio (weight fraction) l _i ; cut length (mm) of the i-th (type) SF d _i ; single fiber denier (de) constituting the i-th (type) SF, where a ₁ + a ₂ + ... a _i + ... + a _n = 1 i = 1 to n

In order to obtain a BCF-mixed carpet yarn used in the present invention from such SF, a spinning method commonly used in the art may be adopted.
For example, the semi-worsted method is a preferable example, and the raw cotton is
After the card process and the gil process, the spinning machine is applied, and the BCF is mixed and wound as described above. The obtained carpet yarn may be used as a single yarn, or may be used as a twin yarn or a triple yarn as required.

The carpet yarn of the present invention is formed by mixing a specific amount of BCF with the above SF. Where B
CF is a long fiber filament having a three-dimensional random crimp, for example, a polyamide long fiber filament such as nylon 6 or nylon 6,6, a polyester long fiber filament such as polyethylene terephthalate or polybutylene terephthalate, and further polypropylene. Three-dimensional random crimps are given to the filaments by subjecting filaments to fluid injection processing, indentation crimping, or the like. When BCFs of the same kind or different kinds of shade dyeing type and / or different dyeing type BCF are twisted or fluid entangled to form a composite, a multicolored carpet yarn and a carpet can be obtained. The total denier of BCF mixed is 300 to 2,000 de,
It is preferably 400 to 1,600 de, and 300 de
When the amount is less than the above, the amount of hair loss increases and the fuzz appearance, abrasion resistance and elastic recovery force decrease, while when it exceeds 2,000 de, the number of fluffs decreases and the fluffy texture effect cannot be obtained. In addition, B
The single fiber denier that constitutes the CF is preferably 3 to 20.
de, more preferably about 5 to 15 de.

The mixing ratio of SF and BCF is S
F is 20 to 90% by weight and BCF is 80 to 10% by weight. If the amount of SF is less than 20% by weight, the amount of fluff is too small to obtain the texture effect due to the fluff, while if it exceeds 90% by weight, the amount of fluff is increased, and the BCF mixing effect such as abrasion resistance and elastic recovery power Is reduced. In order to take advantage of the characteristics of SF and BCF and obtain a carpet with little play hair, SF
It is preferable that the mixed amount of 15 to 75% by weight.

In the carpet yarn of the present invention,
The fluff coefficient (K) defined by the general formula (I) is preferably 10 to 150 (ends / cm), more preferably 15 to 130 (ends / cm). 10 (e
If it is less than nds / cm), the fluff texture of SF is poor, while if it exceeds 150 (ends / cm), the play hair is so often generated that it is difficult to put to practical use.

The carpet yarn of the present invention comprises S
The average cut length of F ranges from short (lower limit = 75 mm) to long (upper limit = 250 mm), but since BCF is mixed and SF and BCF are integrated, strong twisting is applied to impart focusing properties. It is not necessary (may be done), and may be a sweet twist to such an extent as to impart the sizing property as a normal spun yarn. In this case, the condition of sweet twist is that the twist coefficient (α) is preferably 40 to 120, more preferably 5
0 to 90, and the sweet twisted yarn is heat set as necessary. Here, the twist coefficient (α) is defined as T / √ (Nm), where Nm is the count of the spun yarn (carpet yarn) and T is the number of twists (T / m). Thus, as the form of the carpet using the carpet yarn of the present invention, not only the loop pile carpet but also a desired carpet style can be expressed from velor tone to plush tone, saxony, and shaggy.

For example, in order to obtain a loop pile carpet, the long and short composite carpet yarn of the present invention is
1,000 g / m ² , preferably 300-900 g / m
² basis weight and 3-10 mm, preferably 3.5-9
Tuft to a loop pile length of mm.

To obtain a velour-like carpet, the carpet yarn of the present invention is used in an amount of 250 to 900 g / m ² ,
The basis weight is preferably 300 to 600 g / m ² , and 3 to
Tuft to a cut pile length of 10 mm, preferably 4-8 mm. Conventional polyester spun yarn for carpet, for example, has a drawback that the dyeing temperature is high and the twisted form is heat set. In order to overcome this and obtain a velor-like carpet, a velor feeling (pulling property) was expressed by spinning cotton dyed or spun-dyed cotton. In contrast,
Since the number of twists of the carpet yarn of the present invention can be reduced even when the yarn is dyed, the influence of the twisted form at the time of dyeing can be reduced, and a soft velor in which each single fiber is well opened can be obtained. it can. If necessary, the pile hairs can be made uniform through a hair splitting (lasing), a polisher step, and a shirring step.

On the other hand, as in the conventional method, it is possible to increase the number of twists to express the plush tone or the pencil point property of Saxony. For example, in order to obtain a plush carpet, the long and short composite carpet yarn of the present invention has a twist coefficient (α) of 40 to 120, preferably 60.
To 110, preferably 17 for dry heat, for example.
It is heat-set at 0 to 210 ° C., and more preferably at 180 to 200 ° C., and this is set to 400 to 1,000 g / m ² ,
The weight is preferably 500 to 800 g / m ² , and 3 to
Tuft with a cut pile length of 10 mm, preferably 4-8 mm.

To obtain a Saxony carpet,
The long and short composite carpet yarn of the present invention has a twist factor (α) of
40 to 140, preferably 60 to 100, and twisted two or more to make a further twist of 55 to 110.
%, Preferably 60 to 100%, twisted first, and then subjected to the same dry heat treatment as above to obtain 600 to
1,500 g / m ² , preferably 800-1,400 g
/ M ² basis weight and 5 to 20 mm, preferably 6 to 1
Tuft to a cut pile length of 5 mm.

The number of effective fluffs (E) of various carpets obtained by using the long and short composite carpet yarn of the present invention.
K) depends on the single fiber denier (de), but is usually 20
0 to 2,500 (ends / cm ² ), preferably 25
It is about 0 to 2,000 (ends / cm ² ) (when the single fiber denier is around 8 de) and is 200 (ends /
If it is less than cm ² ) even if bulky BCF is mixed, the number of fluffs is too small and the bulkiness deteriorates.
If it exceeds 500 (ends / cm ² ), play hair frequently occurs even if BCF is mixed, and the fuzz appearance deteriorates.

The various carpets using the long and short composite carpet yarn of the present invention have excellent appearance characteristics, practical function characteristics, and comfort. That is, the long and short composite carpet yarn used is mainly composed of SF, and has gloss, color pattern, pattern uprightness, covering property, and volume feeling. In addition, since the long and short composite carpet yarns used are integrated by mixing SF with BCF, the bulkiness and elasticity of the fluff with a small amount of SF are high due to the bulkiness due to the three-dimensional random crimping of BCF. It is excellent in wear resistance, elastic recovery, and fuzz resistance, and has less amount of play hair. Further, the long and short composite carpet yarns to be used have different electric charge signs of generated electricity when polyester fiber or polypropylene fiber is used for SF and polyamide fiber is used for BCF (polyester fiber, polypropylene fiber = plus). , Polyamide fiber = minus), suppresses the generation of static electricity and has excellent antistatic properties. Also, the wear resistance and bulkiness of polyamide fibers, the soft touch of polyester fibers,
Excellent elasticity, cushioning, touch and heat retention.

[0057]

EXAMPLES The present invention will be described more specifically below with reference to examples. In addition,% of the mixing ratio in the examples is based on weight. Example 1, Comparative Example 1 A polyester (PET) indented crimped short fiber (SF) having a single fiber denier of 8 de and an average cut length of 192 mm,
Nylon 6 filament filament (BCF) (1,400 de / 120 fil) with three-dimensional random crimp is mixed, semi-cardia spinning is performed, and polyester of metric number 3 (3,000 de) with a twist number of Z90T / M. S
A carpet yarn in which F and nylon BCF were integrated was obtained. The SF mixture ratio R of this carpet yarn is 0.533 (53.3%), and the BCF mixture ratio is 0.467.
(46.7%) (Example 1).

This carpet yarn was piled on a tuft machine of 1/10 gauge with a pile length of 9.0 mm and stitches of 7.6 pieces.
Tufted into the inch to obtain a velour-like carpet. The back surface of the carpet was backed with a carpet backing agent made of SBR resin, and the root of the pile was completely fixed. Table 2 shows the results. As is clear from Table 2, in Example 1, the fluff coefficient of the carpet yarn was 21 (en).
ds / cm) and the pile fluff loss rate is 0.7
%, The fuzz appearance was 4.0 grade, and a carpet with little play hair was obtained. Further, the compression retention rate by the Tetrapot Walker Test (TPWT) method is 67%, and it is understood that the durability is also excellent.

On the other hand, in Comparative Example 1, polyester S
A spun yarn (carpet yarn) was produced in the same manner as in Example 1 except that only F was used, and a velour-like carpet was obtained in the same manner. The results are also shown in Table 2. In Comparative Example 1,
The pile fluff depilation rate was 0.8% and the fuzz appearance was 4.0 grade, but it can be seen that the compressibility retention rate by the TPWT method was 59% and the durability was poor.

Example 2, Comparative Example 2 In Example 2, polyester SF (single fiber denier =
3.5 de, average cut length = 93 mm, and polyester SF (single fiber denier = 12 de, average cut length = 1)
32 mm) in a weight ratio of 2: 3, cotton is passed through a spinning process, and nylon BCF (1,
000 de / 56 fil) is mixed, the metric number 5
No. (1,800 de) polyester SF and nylon B
A carpet yarn integrated with CF was obtained. Using these two carpet yarns, ply-twisted yarns of ply-twisted S180T / m [twisting factor (α) = 80.5] and ply-twisted Z180T / m (100% of the number of ply-twisted yarns) were produced, and then manufactured by Superva The heat-setting of the twisted form was carried out by the continuous heat setting machine at 140 ° C. to obtain a carpet yarn. Using this carpet yarn, a saxony carpet was obtained.

In Comparative Example 2, as the SF, the single fiber denier was 3.5 de and the average cut length was 93 mm, and the SF was 8 d.
Polyester SF100% in which cotton of e × 102 mm was mixed at a ratio of 1: 1 by weight, the metric number 5 (1,
A plied yarn was prepared from a spun yarn of 800 de), and a saxony carpet was obtained in the same manner as in Example 2. Table 2 shows the results. Example 2 is a carpet yarn and saxony carpet within the scope of the invention and has excellent carpet performance. On the other hand, Comparative Example 2 is SF100.
It can be seen that the carpet yarn is a% used carpet yarn, and the resulting carpet has a lot of play hair, an inferior fuzz appearance, a low compressibility retention rate and an inferior durability.

Example 3 Polyester SF 12 de × 132 mm and 8 de × 1
02 mm and cotton mixed at a ratio of 1: 1 by weight,
800 de of acid deep dyeing type and cation dyeable type which are different dyed nylon BCF in spinning process through spinning process.
/ 68fil is mixed, and the SF mixture ratio R is 0.466 (4
6.6%, which is the third metric number (3,000d)
The carpet yarn of e) was obtained. This carpet yarn was heat-treated at 210 ° C. by a heat-setting machine manufactured by Suezsen, and then tufted to a pile length of 12 mm and stitches of 8.0 lines / inch by a 1/8 inch gauge tuft machine, and then dyeing, backing, After finishing, multicolor (3
A (color) mix plush carpet was obtained. The results are shown in Table 3. The pile fluff loss rate was 0.6%, the fuzz appearance was 4.0 grade, there was little idle hair, and the compressibility retention rate by the TPWT method was 72%, and a carpet with good durability was obtained.

Comparative Example 3 Using the same polyester SF as in Example 3, SF100%
A plain plush carpet was made by the same standard and manufacturing method as in Example 3. The results are shown in Table 3. According to Comparative Example 3, the pile fuzz loss rate is 1.0%, the fuzz appearance is grade 3.0, and the compressibility retention rate by the TPWT method is 55%.
Therefore, it was inferior in durability.

Example 4 6de × 192 mm Polyester SF, 1,400
A carpet yarn was obtained in the same manner as in Example 1 except that the polyester BCF of de / 144 fil was used, and a velour-like carpet was obtained in the same manner. The results are shown in Table 4. Example 5 10 de × 127 mm acrylic SF and 1,000 d
A carpet yarn was obtained in the same manner as in Example 2 except that e / 56 fil nylon BCF was used, and a saxony carpet was obtained in the same manner. The results are shown in Table 4. It is understood that all of Examples 4 to 5 are carpet yarns and carpets within the scope of the present invention and have excellent carpet performance.

Examples 6 to 7 and Comparative Example 4 The average cut length was 80 mm (Example 6) or 240.
A velour-like carpet was obtained in the same manner as in Example 1 except that polyester SF having a thickness of mm (Example 7) and polyester SF having an average cut length of 60 mm (Comparative Example 4) were used. The results are shown in Table 4. All of Examples 6 to 7 are carpet yarns and carpets within the scope of the present invention, and have excellent carpet performance. On the other hand, Comparative Example 4 is an example in which the average cut length of SF is less than the lower limit of the present invention, the pile fluff depilation rate is high, the fuzz appearance is poor, and the compressibility retention rate is low.

Example 8 Polyester SF and nylon BCF were integrated by performing the same twist setting as in Example 2 except that monofilament denier 8 de, average cut length 132 mm polyester SF, and 800 de / 68 fil nylon BCF were used. In addition, a carpet yarn having a metric count of 5 (twist number: Z180T / m) was obtained. Used for this carpet yarn,
A plush carpet was obtained by tufting with a 1/10 gauge tufting machine to a pile length of 8.0 mm and 12.7 stitches / inch and backing in the same manner as in Example 1. The results are shown in Table 5.

Example 9 A loop pile carpet was obtained in the same manner as in Example 1 except that the twin carpet yarn obtained with the twist number of S100T / M and Z100T / m was used and the pile was not cut. The results are shown in Table 5. All of Examples 8 to 9 are carpet yarns and carpets within the scope of the present invention, and have excellent carpet performance.

[0068]

[Table 2]

[0069]

[Table 3]

[0070]

[Table 4]

[0071]

[Table 5]

[0072]

According to the long and short composite carpet yarn of the present invention, the occurrence of idle hair is suppressed, the unique texture and appearance of spun yarn are maximized, and the three-dimensional random crimped filament fiber (BCF) is used. It is possible to provide a carpet that can also exhibit the durability (compression retention rate) possessed by, and further, it has a good texture without using a low-melting fiber, and it can be used not only for loop pile carpets, but also for velour-like, plush. We can provide carpets with little play hair in a wide range from tones, saxony and shaggy.

[Brief description of drawings]

FIG. 1 is a graph showing the relationship between the average cut length of SF constituting a carpet yarn (spun yarn) and the fluff coefficient (K).

FIG. 2 is a diagram schematically showing a side surface when tufting a carpet yarn as a cut pile on a base fabric.

FIG. 3 is a model diagram showing how single fibers constituting a carpet yarn exist in a tufted pile.

FIG. 4 is a graph showing the relationship between the pile height and pile fluff loss rate of carpet piles (spun yarns) when the average cut length of SFs forming the yarns is changed.

FIG. 5 is a graph showing the relationship between the number of effective fluffs (EK) when the average cut length of SF constituting the carpet yarn (spun yarn) is changed, and the pile fluff depilation rate or fuzz appearance.

FIG. 6 is a graph showing the relationship between the mixing ratio of SF and the pile fluff removal ratio in a long / short composite carpet yarn of polyester SF and nylon BCF.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takayoshi Yakura 1-6-7 Minamihonmachi, Chuo-ku, Osaka-shi, Osaka Teijin Limited Osaka headquarters

Claims (14)

[Claims] 1. A carpet yarn having a thickness of 2 Nm to 10 Nm (900 to 4,500 denier) expressed in metric count (Nm), the staple yarn 2 having an average cut length of 75 to 250 mm.
A long-short composite carpet yarn, which is mainly composed of 0 to 90% by weight, and 80 to 10% by weight of a three-dimensional random crimped long fiber filament. 2. A three-dimensional randomly crimped filament filament is located inside a yarn so that staple fibers are wound around the filament, and at the wrapping interface between the two, one end of at least a portion of the staple fiber is formed. The long-short composite carpet yarn according to claim 1, wherein the long-short composite carpet yarn is integrated while being inserted into the three-dimensional randomly crimped long fiber filament. 3. The carpet yarn has the following general formula (I):
The fluff coefficient (K) defined by 10 to 150 (ends /
cm) The long and short composite carpet yarn according to claim 1 or 2. Fluff coefficient (K) = {[(De / de) / L] × 2} × R ... (I) [In the above general formula (I), De is the total denier of the carpet yarn and corresponds to the above metric number. 900 to 4,50
0 denier, de is the average single fiber denier of the staple fiber 3 to 20 denier, L is the average cut length of the staple fiber, and here, for convenience, the unit of "cm" is adopted, and the value is 7.5 to 25 cm, R is a mixing ratio of staple fibers in the carpet yarn and is a numerical value of less than 1. ] 4. The long and short composite carpet yarn according to claim 1, wherein the staple fiber has an average cut length of 100 to 230 mm. 5. The long-short composite carpet yarn according to claim 1, wherein the staple fiber is composed of at least one selected from the group consisting of polyester fiber, polyacrylonitrile fiber and polypropylene fiber. 6. The three-dimensional randomly crimped filament fiber is composed of at least one selected from the group consisting of a polyamide fiber, a polyester fiber and a polypropylene fiber, according to any one of claims 1 to 3. Long and short composite carpet yarn. 7. A play fiber formed by tufting the long-short composite carpet yarn according to claim 1 with a basis weight of 250 to 1,000 g / m ² and a loop pile length of 3 to 10 mm. Less loop pile carpet. 8. The number of effective fluffs (EK) defined by the following general formula (II) is 250 to 2,000 (ends / cm ² ).
The loop pile carpet with less play hair according to claim 7. Valid fluff number (EK) = [(gauge needle number) (number stitches) (pile height) × 2 × K] / (2.54 × 2.54) (ends / cm 2) ··· (II) [ In the above general formula (II), the number of gauge needles is the needle density of the tufting machine (lines / inch), the stitch is the number of piles driven (lines / inch), the pile height is cm, and K is the fluff coefficient. ] 9. A velor with little idle hair formed by tufting the long / short composite carpet yarn according to any one of claims 1 to 6 with a basis weight of 250 to 900 g / m ² and a cut pile length of 3 to 10 mm. Style carpet. 10. The number of effective fluffs (EK) defined by the general formula (II) is 250 to 2,000 (ends / c).
m ² ) The velor-like carpet with less play hair according to claim 9. 11. The long and short composite carpet yarn according to claim 1, wherein the twist coefficient (α) is 40 to 120.
A plush carpet with little idle hair, which is obtained by twisting the yarn with a tuft, and tufting this with a basis weight of 400 to 1,000 g / m ² and a cut pile length of 3 to 10 mm. 12. The number of effective fluffs (EK) defined by the general formula (II) is 250 to 2,000 (ends / c).
The plush-like carpet with less play hair according to claim 11, which is m ² ). 13. A twisting coefficient (α) of 40 to 140 for the long and short composite carpet yarn according to any one of claims 1 to 6.
Then, a plurality of the ply-twisted products are aligned and ply-twisted at a twist number of 55 to 110% of the ply-twisted product.
A saxony carpet with a unit weight of 1,500 g / m ² and tufted with a cut pile length of 5 to 20 mm and little play. 14. The number of effective fluffs (EK) defined by the general formula (II) is 250 to 2,500 (ends / c).
m ² ). The saxony carpet with less play hair according to claim 13.