JPS64497B2 - - Google Patents

Description

[Detailed description of the invention]

(a) Field of Industrial Application The present invention relates to a method for producing polyester saxony carpet, and more particularly, to a method for producing polyester saxony carpet having excellent bulkiness, pencil point property, and hand. (b) Prior art Saxony carpet is a carpet that has cut piles of 18 mm or less in length, which are usually twisted and set, and the ends are gathered together.The pile yarn for this Saxony carpet has traditionally been made of polyamide Fibers were used exclusively. Recently, polyester fibers have also come to be used as pile yarns for carpets, but when polyester fibers are used as pile yarns for Saxony carpets, the pile yarn has poor twist and set properties, and the carpet surface is rubbed several times. This method has not been put to practical use until now because the tips of the pile yarns become frayed and the cohesion (pencil pointability) of the ends of the pile yarns becomes extremely poor. On the other hand, Japanese Patent Publication No. 44-20497 describes that when a latent three-dimensionally crimpable neutral polyester fiber is subjected to relaxation heat treatment to develop three-dimensional crimp, mechanical crimp may be applied before the heat treatment. There is. Furthermore, Japanese Patent Publication No. 54-39490 describes that a tufted carpet is made by mechanically crimping a latent three-dimensionally crimped polyester fiber, subjecting it to relaxation heat treatment, and cutting it into staples. . In addition, special public service in 1987
Publication No. 54568 describes that latent three-dimensionally crimped hollow polyester fibers are mechanically crimped, cut into staples, and then heat treated to produce highly crimped fibers, and the resulting fibers are used for carpeting. It has been suggested that it can be used for various purposes. However, the techniques described in these publications are aimed at improving the crimpability and bulkiness of crimped fibers, and are aimed at improving the pencil point properties of polyester saxony carpet. However, there is no teaching as to what measures should be taken to improve pencil pointability. (c) Problems to be Solved by the Invention The present invention improves the poor pencil point property caused by poor twist setting properties of polyester fibers,
The purpose is to provide an excellent polyester saxony carpet. (d) Means for solving the problems The present invention provides mechanical crimping to latent three-dimensionally crimped polyester fibers, then develops the crimps, and further
Made of short polyester fibers treated with moist heat above 100°C, and has a peak heat shrinkage stress of 100 to 200°C.
This is a method for producing polyester saxony carpet, which is characterized in that a plurality of spun yarns existing between the two are twisted together, then heat set, and then tufted as pile yarn. Polyester in the present invention refers to aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, 1,2-bis(P-carboxyphenoxy)ethane, and 2,2-bis(P-carboxyphenoxy)propane. acids, aliphatic dicarboxylic acids such as adipic acid and sebacic acid or their esters and ethylene glycol,
It is a polyester synthesized from a diol compound such as diethylene glycol, neopentyl glycol, or cyclohexane-1.4 dimethanol, and polyethylene terephthalate is particularly preferred. In addition, polyesters include polyalkylene glycol, glycerin, pentaerythritol, methoxypolyalkylene glycol, bisphenol A, para (β-hydroethoxy)benzoic acid, 3-
In addition to methoxy-4(β-hydroxyethoxy)benzoic acid, sulfoisophthalic acid, etc., copolymers of the above-mentioned carboxylic acids, glycols, etc. may also be used. Latent three-dimensional crimpable polyester fiber is obtained by composite spinning of two types of polyester side-by-side, or by cooling the spun yarn asymmetrically. It means a fiber that can develop crimp. In the present invention, after applying mechanical crimp such as gear crimp or push crimp to this latent three-dimensional crimp polyester fiber, the polyester short fiber is made from polyester staple fibers which are made to develop crimp and further treated with moist heat at 100°C or higher. The spun yarn is used as the pile yarn. Crimp development treatment is dry heat
Relaxation heat treatment at 120 to 180°C is effective, and treatment at 135 to 170°C is particularly preferred.
If the crimp development treatment temperature is low, the crimp will be low, the yarn will become tight due to twisting during spinning, and the bulkiness of the yarn will not increase due to moist heat setting after twisting. Furthermore, if the processing temperature is too high, crimp development during wet heat setting after twisting will be poor, and the bulkiness and pencil pointability of the yarn will be at a low level. Furthermore, it is necessary to treat the crimped raw cotton with moist heat at 100°C or higher. By this treatment, the crimped yarn is set with moist heat, which weakens the crimping a little, making the crimping latent, making it easier to spin, and making it easier to wind the yarn by heat setting after it has been twisted into yarn. Shrinkage occurs easily, and a pile yarn that is bulky and has good pencil point properties can be obtained. On the other hand, if the moist heat setting temperature is low, it is difficult for crimp to be latent and the spinnability is poor, and also it is difficult for crimp to occur due to heat setting after plying and twisting.
Bulky properties and pencil point properties tend to be defective. These moist heat treatments may be carried out by steam setting or may also be carried out concurrently with dyeing. Crimp characteristics of the three-dimensional crimp-expressing fiber (JIS1074-65
(Measurement by), the number of crimps per inch is 7 to 12 and the degree of crimp is 15 to 25%.
The degree of crimp is preferably 18 to 23%. If the crimp performance is too low, the spinnability will be poor and the bulky property will be low in wet heat setting after twisting. On the other hand, if the crimp performance is too high, the spinnability will be poor, the resulting spun yarn will have many spots and fuzz, the setting property in moist heat setting will be insufficient, and the pencil point property will also be poor. By using such a spun yarn, the twist setting property of the pile yarn is improved, the pencil point property is improved, and the bulky property is increased. It is desirable that the three-dimensionally crimped polyester fiber be a hollow fiber. The hollowness ratio of the hollow fibers is preferably 10% or more and less than 50%, more preferably 20% or more and less than 40%.
If the hollowness ratio is too large, the hollow portion is likely to collapse when it is made into a carpet, and the shape change due to compression etc. will be large, which is not preferable. On the other hand, if the hollowness ratio is too low, latent crimp will be difficult to develop and the bulkiness and pencil point properties of the yarn will deteriorate. Furthermore, the above-mentioned spun yarn has a peak of heat shrinkage stress.
It is necessary that the temperature is between 100 and 200°C, particularly preferably between 115 and 170°C. If the peak of heat shrinkage stress does not exist, the pile yarn will not be able to fully develop crimp at the heat setting temperature, the twist and setting properties of the pile yarn will be poor, and the pencil point property will be poor. I end up. regular polyester fiber
Even if it is spun after wet heat treatment at 100℃ or higher, the peak of heat shrinkage stress only exists near the melting point.
It does not exist between ~200℃. In order to obtain a spun yarn with a heat shrinkage stress peak within the range of 100 to 200°C, the above-mentioned latent three-dimensionally crimped polyester fiber is mechanically crimped, and then the crimp is developed to form the spun yarn. do it. Here, the heat shrinkage stress is measured by the following method. First, the ends of the spun yarn sample to be measured are tied together to form a loop, and the loop is hung between the upper and lower hooks of the measuring device. In this case, the material length between the upper and lower hooks should be 10 cm. Kanebo Engineering is the measuring device.
Using a thermal stress measuring machine type KE- manufactured by Co., Ltd., an initial load of (denier of spun yarn)/30g was applied, and 2.5
The temperature is raised from room temperature to 250°C at a rate of °C/sec to obtain a relationship curve between heat shrinkage stress and temperature. From this relationship curve, determine the temperature at which the thermal shrinkage stress peaks. The spun yarn is preferably in the range of 15th (metric count, 600de) to 3rd count (metric count, 3000de) as a single yarn before plying and twisting, and a more preferable range is 12th count (metric count, 750de) to 4th count (meter count, 3000de). metric count, 2250de). If this yarn count is too small, the ability to develop crimps during moist heat treatment after plying and twisting is weak, and there is a tendency for bulky properties and pencil point properties to decrease. On the other hand, if the count is too large, the diameter of the single yarn becomes too large, resulting in insufficient pencil point properties. The number of single yarns to be twisted is preferably 2 to 4, more preferably 2. If the number of plied yarns becomes too large, the binding force of the plied yarns will be lost, and the durability of the carpet will decrease. Next, a plurality of the above spun yarns are twisted together and heat set. It is desirable to perform this heat setting using moist heat within the range of 120 to 160°C, and in order to avoid deteriorating the bulkiness, it is preferable to set the cheese using a continuous moist heat setting that does not apply tension rather than setting the cheese under tension. (For example, treatment with a superbasetter) is preferably employed. By this heat setting, the heat shrinkage stress which has a peak between 100 and 200 DEG C. is relaxed, thereby improving the bulkiness and setting properties of the yarn, making it possible to obtain a preferable Saxony carpet pile yarn. The thus obtained twisted heat-set yarn is tufted in a conventional manner to form a Saxony carpet. (E) Examples Hereinafter, the present invention will be explained in more detail with reference to Examples. Example 1.2, Comparative Example 1.2 Polyethylene terephthalate with an intrinsic viscosity of 0.64 was spun from a spinneret with 200 nozzles at 1010 m/min.
After spinning at a spinning speed of 10 minutes, followed by two-stage stretching (first stage stretching 2.8 times in hot water at 70°C and second stage stretching 1.05 times in hot water at 90°C), relaxation at 160°C for 20 minutes. Heat treated to develop crimp, and then heated to 130°C
After processing for 30 minutes, it was cut into lengths of 153 mm. The fineness of the obtained short fibers was 6de. At this time, in Example 1, a hollow nozzle was used and cooling air was blown from one side of the spun yarn at a speed of 3.5 m/sec to perform anisotropic cooling, thereby forming the latent three-dimensional crimpable fiber. After stretching, the film was subjected to a relaxation heat treatment after being crimped. In addition, in Example 2, no hollow nozzle was used,
Other conditions were the same as in Example 1. On the other hand, in Comparative Example 1, the indentation crimp of Example 1 was omitted, and in Comparative Example 2, the anisotropic cooling of Example 1 was not performed. Each of the four types of raw cotton obtained in this way was
After dyeing in a dye bath at 130℃ for 30 minutes, 6 count (meter count, 1500de) spun yarn (230T/m, Z
Twist), and then combine and twist two of these spun yarns to create (190T/
(m, S twist), and was set in a wet heat setting at 145°C for 20 minutes in a skein state. After that, gauge 1/8 inch, stitches 9.5 times/inch, pile height 10 mm, tuft weight 1035 g/m ²
Each plied set yarn was tufted under the following conditions, and then subjected to backing, drying, and shearing treatments to produce a Saxony carpet. The temperature at which the heat shrinkage stress peak of each spun yarn appears,
The evaluation results for the carpet and the carpet were as shown in the following table.

[Table] ◎: Extremely good ○: Good △: Slightly poor ×
: Poor As is clear from the table, the carpet made by the method of the present invention has great bulkiness, the pile tip hardly loosens even after long-term use, and has excellent pencil point properties. Moreover, the texture was also good (Example
1.2). On the other hand, the case where only anisotropic cooling was performed without indentation crimp (Comparative Example 1) and the case where only indentation crimp was performed without anisotropic cooling (Comparative Example 2),
In both cases, the bulkiness is low, the tip of the pile falls apart just by rubbing it hard a few times, the pencil pointability is extremely poor, and the texture is not very good, making it impossible to put it to practical use as Saxony carpet. It was hot. Comparative Example 3 In Example 1, the moist heat treatment after the appearance of crimp was carried out at 80°C.
The process was carried out for 30 minutes, and the other conditions were the same as in Example 1 to obtain a spun yarn. The peak temperature of heat shrinkage stress of the obtained spun yarn was 130°C. When a Saxony carpet was prepared using this spun yarn under the same conditions as in Example 1, the bulkiness, pencil pointiness, and hand were all somewhat poor. Example 3 In Example 1, instead of performing anisotropic cooling,
Composite hollow fibers (hollowness ratio 34%) made by side-by-side composite of polyethylene terephthalate with an intrinsic viscosity of 0.64 and polyethylene terephthalate with an intrinsic viscosity of 0.50 obtained by copolymerizing 5 mol% of 5-sodium sulfoisophthalic acid, etc. When a Saxony carpet was prepared under the same conditions as in Example 1, it had very good bulkiness, pencil pointiness, and hand. (F) Effects of the Invention According to the method of the present invention, it is possible to obtain a Saxony carpet that has excellent bulkiness and texture, good twist-setting properties, and excellent pencil point properties, and is far superior to conventional polyester fibers that have been put to practical use. It had the remarkable effect of making Saxony carpet, which was difficult to use, practical.
Its significance is extremely large.

Claims (1)

[Scope of Claims] 1 Consisting of polyester short fibers which are mechanically crimped to latent three-dimensionally crimped polyester fibers, developed to develop crimps, and further treated with moist heat at 100°C or higher,
A method for producing a polyester saxony carpet, characterized in that a plurality of spun yarns having a heat shrinkage stress peak between 100 and 200°C are twisted together, then heat set, and then tufted as pile yarns. 2. The method for producing a polyester saxony carpet according to claim 1, wherein the latent three-dimensionally crimpable polyester fiber is a hollow fiber. 3. A method for producing a polyester saxony carpet according to claim 1 or 2, wherein the heat setting is carried out at 120 to 160°C with moist heat.