JP5230144B2 - Pile product using polypropylene multifilament mixed yarn and method for producing the same - Google Patents

Description

  The present invention relates to a pile product made from polypropylene crimped fiber, which uses a polypropylene fiber mixed yarn having no softening yarn, having a feeling of napping, high bulkiness, and having a soft texture. The present invention relates to a product and a manufacturing method thereof.

Polypropylene crimped yarns are widely used in industrial applications such as textiles because they are excellent in lightness, water repellency, easy recyclability and the like.
Properties required for polypropylene pile products include bulkiness and texture. In order to enhance these characteristics, for example, adjustment of the single fiber fineness of the carpet yarn, adjustment of the cross-sectional shape of the yarn, and crimping are performed. However, a highly crimped fiber that is intended to obtain a bulky feeling, and a pile product made from a modified cross-section crimped fiber is hard. Therefore, in order to obtain a pile product with a soft feeling, a crimped fiber with a soft feeling is required.
However, there are several problems in obtaining crimped fibers with a soft feeling. Specifically, in order to obtain a filament-crimped fiber having a fineness, there are problems such as limitations on pigments and dyes in terms of the yarn production. Further, a crimped fiber having a fine single fiber fineness is poor in yarn-making property. The resulting fiber product also has the disadvantage that the fibers are intertwined.
Moreover, in order to obtain a low crimped fiber, the stretchability of the crimped yarn is low in terms of the yarn-making property, and fluctuations in tension before winding cannot be absorbed, which may deteriorate the yarn-making property. In addition, when a low crimped yarn is used as a fiber product, the stretchability of the crimped yarn is low, the fluctuation of the tension before the needle cannot be absorbed, and the crimped yarn does not easily come off from the looper and the passage through the tuft process is deteriorated. . It could not be used for pile products having a soft feeling and having a yarn forming property and passing through a tuft process.

Therefore, many researches and developments have been made on the development of a polypropylene fiber carpet having good tuft-passability and a soft texture. Patent Document 1 discloses a flat side arm having a curved tip. A substantially flat side rectangular central section (S-shaped flat cross section yarn) having a cross section has been proposed.
Patent Document 2 also proposes a fabric made of a pile containing polyester fibers having a flat cross section. Patent Document 3 also proposes a flat fiber with a polypropylene terephthalate polyester fiber and a flatness ratio of 1: 2 to 1:10.
Patent Document 4 proposes to use a mixed fiber of a flat cross-sectional yarn of polyester fiber and a hollow cross-sectional yarn of polyester fiber.

However, Patent Document 1 has a unique cross-sectional shape of the two discharge portions, and the resin used is nylon 6 and 6, which is a dyed carpet and inferior in easy recyclability.
In Patent Document 2, the cross section including the polyester fiber is a fabric from a flat cross section fiber, and is not an easily recyclable polypropylene fiber product.
Moreover, patent document 3 is a polypropylene terephthalate type polyester fiber, and is not an easily recyclable polypropylene fiber.
Furthermore, Patent Document 1 and Patent Document 2 describe that the texture of the pile is soft and soft to the touch. However, it is a method for enhancing the bulkiness and the nap feeling with these softness and soft touch, and is not a method for developing a soft feeling by defibration and low crimping in post-processing.

Patent Document 3 is also an improvement of the texture, pile pile, hair fallability, texture change (deterioration), etc., which also develops soft feeling by defibration and low crimping in post-processing. Not a way. A flat fiber has a problem that a single interfiber gap for obtaining bulkiness cannot be obtained from its cross-sectional shape.
Further, the method disclosed in Patent Document 4 is improvement of pile settling, hair fallability, etc., and the resin used is also a polyester resin, and the polyester fiber contains fibers of 2000 ppm to 10,000 ppm, and the fiber cross section is also included. It is a blended yarn of flat cross-section yarn and hollow cross-section yarn, and is not an easily recyclable fiber.

  Further, as a method for obtaining high bulkiness, many methods for making a fiber cross section into a multileaf cross section have been proposed. For example, Patent Document 5 proposes a special Y cross-section fiber having a convex curved surface connected at the tip along the contour of each leaf, substantially having no flat surface, and having 2 to 20 curvature reversals per leaf, All of these do not develop a soft feeling by defibrating in post-processing.

JP-T 8-512102 JP 61-152849 A JP 2000-328393 A Japanese Patent Laid-Open No. 5-230737 JP 2002-88564 A

An object of the present invention is to solve such problems in the prior art, and provide a pile product made of polypropylene fibers that has good tuft passage in post-processing and excellent spinning stability. There is to do.
Accordingly, an object of the present invention is to provide a pile product having a good tuft passage property, a high bulkiness and a good texture, and a method for producing the same.

The first gist of the present invention is composed of a polypropylene crimped yarn in which a polypropylene multifilament yarn (A) and a polypropylene multifilament yarn (B) satisfying the following conditions (1) to (3) are mixed , A pile product having a defibrated cut pile, which is a polypropylene pile product that satisfies the following conditions (4) to (6).
(1) Polypropylene multifilament yarn (A) is the bulk density 11 ^(cm 3 / g) following polypropylene multifilament yarn
(The bulk density (cm ³ / g) was measured according to the method described in the specification.)
2 is commingled proportions of polypropylene multi filament yarn (B) is the bulk density 14 ^(cm 3 / g) or more polypropylene multifilament yarn (3) polypropylene multifilament yarn (A) and polypropylene multifilament yarn (B) Range of 1: 2 to 2: 1 (4) Work of compression (WC) ≧ 0.29 g · cm / cm ²
(5) Compression ratio (EMC) ≧ 18.5%
(6) Hardness of compression (LC) ≧ 0.70non

Furthermore, the second gist of the present invention resides in a method for producing a polypropylene pile product including the following steps (a) to (c) .
(A) The blend ratio of the polypropylene multifilament yarn having a bulk density of 11 (cm ³ / g) or less and the polypropylene multifilament yarn having a bulk density of 14 (cm ³ / g) or more is in the range of 1: 2 to 2: 1. the pile tufted commingled polypropylene crimped yarn
(B) Cut the pile
(C) Perform defibration processing

The pile product of the present invention has a high bulkiness and a soft texture. Soft tufted polypropylene fiber with moderate crimpability to obtain process passability in the tufting process of pile products, blended yarn with polypropylene fiber having bulkiness, and defibrating after tufting process By doing so, a gap between single fibers is obtained for both the flat fibers and the Y-shaped cross-section fibers.
Since the pile product made of the polypropylene crimped fiber of the present invention has a soft texture and excellent bulkiness, it can be suitably used for vehicle option mats, rug / peace carpet home use and the like.

Hereinafter, the present invention will be described in detail.
The polypropylene multifilament fiber used in the pile product of the present invention is composed of a polypropylene multifilament yarn (A) having a bulk density of 11 (cm ³ / g) or less and a polypropylene multifilament yarn having a bulk density of 14 (cm ³ / g) or more ( B), and it is necessary that the mixing ratio is 1: 2 to 2: 1. When the blend ratio of the polypropylene multifilament yarn (A) having a bulk density of 11 (cm ³ / g) or less and the polypropylene multifilament yarn (B) having a bulk density of 14 (cm ³ / g) or more is less than 1: 2. It is not preferable because it lacks softness. When the blend ratio exceeds 2: 1, the softness increases, but the bulkiness is inferior, which is not preferable.

As the polypropylene multifilament yarn of the polypropylene multifilament yarn (A) having a bulk density of 11 (cm ³ / g) or less used in the present invention, a flat cross-sectional yarn, a triangular cross-sectional yarn, a round cross-sectional yarn or the like can be used.
Among these, when a flat cross-sectional yarn is used, the flatness is preferably in the range of 3 to 10. More preferably, it is the range of 5-8. When the flatness is less than 3, the bulk height tends to be high and the soft feeling is lacking. When the flatness exceeds 10, the softness is excellent, but the yarn-making property is unstable.

On the other hand, as a polypropylene multifilament yarn of a polypropylene multifilament yarn (B) having a bulk density of 14 (cm ³ / g) or more, a Y-shaped cross-sectional yarn, a hollow cross-sectional yarn, and a cross-sectional yarn having a hollow part partially in the length direction Etc. can be used.

The polypropylene fiber product of the present invention has a compression work (WC) ≧ 0.29 g · cm / cm ² , a compression rate (EMC) ≧ 18.5%, and a compression hardness (LC) ≧ 0.70. is necessary. When the compression work (WC) is less than 0.29 g · cm / cm ² , the fiber product has a poor soft feeling, which is not preferable. Moreover, a soft feeling will become scarce that a compression rate is also less than 18.5%. If the compression hardness (LC) is less than 0.70, the bulkiness is poor, which is not preferable.

The pile product of the present invention has a soft feeling, a fuzzy feeling and a bulky feeling as the polypropylene crimped yarn of the pile is defibrated in the course of its manufacture by the defibrating process to the cut pile after the tufting process. It was one in which there is a feeling of luxury.

  The resin used for the polypropylene multifilament yarn constituting the fiber product of the present invention is not particularly limited, and any commercially available product or any polymer obtained by a conventionally known polymerization method can be used. In addition, the polypropylene multifilament yarn constituting the fiber product of the present invention has a color pigment, a dispersant, a fluorescent brightening agent, a matting agent, a lubricant, an antistatic agent, and a deodorant as long as the physical properties of the fiber are not impaired. Additives such as antibacterial agents and flame retardants may be blended, and the types and amounts of these additives may be different.

Next, the manufacturing method of the polypropylene pile product of this invention is demonstrated.
In the method for producing a polypropylene pile product of the present invention, the blend ratio of a polypropylene multifilament yarn having a bulk density of 11 (cm ³ / g) or less and a polypropylene multifilament yarn having a bulk density of 14 (cm ³ / g) or more is 1. : It is necessary to tuft on a base fabric to make a pile using a polypropylene crimped yarn that has been mixed and crimped in the range of 2 to 2: 1.

Furthermore, in the method for producing a polypropylene pile product of the present invention, it is necessary to perform a defibrating process called a polisher process after the pile is cut by tufting.
In the present invention, by performing this defibrating process, the cut pile is defibrated with the removal of crimps, and a soft, fuzzy and bulky feeling is developed and a high-grade pile product is obtained.

The polypropylene crimped yarn constituting the pile product of the present invention can be obtained by a known melt spinning method. Fibers by melt spinning may be a composite fiber of the fiber core-sheath structure or lamination structure like.
Next, explaining the manufacturing example polypropylene crimped yarn, spinneret with polypropylene resin melted by a melt extruder, as shown in Examples below, the two hole groups with different modification degree in pore geometry Then, a spinning oil is supplied to the surface of the spun yarn, and the yarn is wound up to obtain an undrawn yarn in which two types of yarn are mixed . Undrawn yarn may be carried out stretched as it is continuous, may be stretched after the wound once. Stretching may be performed in one or two or more stages, and the setting of the stretching ratio in the multistage stretching is not particularly limited.

  The undrawn yarn thus obtained is subjected to drawing and hot air crimping. At this time, without winding up the melt-spun undrawn yarn, continuously drawing, drawing hot air crimping simultaneously, direct spinning drawing crimping method entangled with air, or after winding up the undrawn yarn, A crimped yarn can be obtained by using a simultaneous hot-air crimping process, a method of entanglement with air and the like.

In the stretching process, the heat source may be a contact type or a non-contact type. The draw ratio in the draw is preferably 1.5 to 5 times. If the draw ratio is less than 1.5 times, the fiber strength of the obtained filament yarn is low. Increased risk. The stretching temperature is preferably 50 to 130 ° C. When the stretching temperature is less than 50 ° C, the draw ratio is low, and the fiber strength of the obtained filament yarn is low. When the stretching temperature exceeds 130 ° C, yarn breakage occurs. To do.
Next, the obtained soft polypropylene fiber product may be a cut pile carpet, a cut pile carpet in which a cut pile portion is mixed in part, or a cut and loop pile carpet in which a loop pile portion is mixed in part.

  After the pile product is formed, an adhesive is applied to the back surface, and the adhesive is dried and cured to fix the pile, thereby obtaining a soft carpet that is a pile product made of the polypropylene fiber of the present invention. At this time, a lining according to the application, for example, a sheet made of synthetic rubber or vinyl chloride resin or linen may be attached to the back surface of the base material via the adhesive. As the adhesive to be used, any adhesive can be used depending on the use and the material of the backing. For example, it selects suitably according to the kind of the base fabrics, such as acrylic latex or a urethane type adhesive agent.

In addition, the measurement of each characteristic value of the fiber product obtained by this invention was calculated | required and evaluated by the following method.
(The bulk density)
Samples are prepared by bundling the sample and performing a heat treatment at a dry heat temperature of 70 ° C. for 10 minutes, and then the recesses of the sample stage provided with the recesses having a certain width and height shown in FIG. The sample is filled in, the measurement load (240 g) is placed on it, the height (L) after a predetermined time (10 minutes) is read, and the sample protruding from the measuring instrument (side surface of the concave part of the sample table) is cut, The weight of the sample in the sample table was measured, and the bulk density was calculated by the following formula.
Bulk density (cm ³ / g): L × 4 / g
FIG. 1 is a perspective view of a sample table (measuring instrument), and a measurement concave portion is provided above, the width of the concave portion is 1 cm, the length is 4 cm, and the height (depth) is 3 cm. FIG. 2 is a sectional view from the length direction of the measuring instrument, and L indicates the height of the recess.

(Flat rate)
-A fiber is passed through a hole of a measurement thin metal plate (thickness 0.5 mm, hole diameter 0.8 mm).
-Cut the fibers above and below the thin metal plate with a razor.
・ Put on the stage of the optical microscope and take a picture of the cut surface.
-From the photograph, measure the width and length of the fiber cross section, and determine the ratio of the cross section width to the cross section length.
These were repeated 10 times, and the average value was taken as the flatness.

(Crimp rate)
-Bundle the specimens to create a fissile sample thread.
Winding tension: 1 / 15g per D (fineness: decitex)
Number of windings ··· 2 times (change according to fineness)
・ The sample yarn is heat-treated at a dry heat temperature of 80 ° C. for 10 minutes under no load.
-Leave under no load for more than 10 minutes after heat treatment.
・ Apply the measurement load A to one end of the sample yarn and measure the yarn length (L1) after 1 minute.
Measurement load A = D × (1/10) × (2 × number of windings)
・ Leave the measurement load A for 2 minutes.
・ Apply the measurement load B to one end of the sample yarn and measure the yarn length (L2) after 1 minute.
Measurement load B = D × (1/10) × (2 × number of windings)
Calculation formula: Crimp rate (%) = ((L1−L2) / L1) × 100 was used as the crimp rate.

(Compression work amount (WC), the compression ratio (EMC), the hardness of the compression (LC))
Using crimped yarn of polypropylene multifilament commingled 1/8 tufting machine gauge, pile driving density 12 yarns / inch, and tufted pile height 8mm and pile, cut pile carpet cut pile And a sample subjected to polisher processing was measured.
A simple compression tester (KES-FB3 manufactured by Kato Tech Co., Ltd. ) is used for the measurement. A sample larger than the sample pressure plate is set on the pressure plate, and the maximum load is measured under the conditions of a measurement area of 2 cm ² and a measurement speed of 50 sec / mm. Measurement was performed up to 50 gf / cm ² .
1) Work of compression (WC) (g · cm / cm ² ): An index representing the soft feeling of carpet and the feeling of napping and bulkiness, and is obtained as follows. The thickness of the carpet at a pressure 0.5 g / cm ² as (the To), the integral of the pressure P and dT to a thickness (Tm) when a pressure is applied to 50 g / cm ^2.
2) Compression rate (EMC) (%): An index representing the softness of the carpet, which is obtained as follows. The compression rate at the maximum load (50 gf / cm ² ) was obtained from the above To and Tm by the following calculation formula.
[(To−Tm) / To] × 100 (%)
3) Hardness of compression (LC) (non) : An index representing the softness of the carpet and the feeling of napping and bulkiness.
Assume that the carpet thickness at a pressure of 0.5 g / cm ² is (To), and the integrated value of pressure P and dT up to the thickness (Tm) when pressure is applied up to 50 g / cm ² / pressure 0.5 g / cm ² The area of the pressure P up to the thickness (Tm) when the pressure is applied to 50 g / cm ² where the thickness of the carpet at (To) is (To). Note that non means dimensionless.
4) Amount of compression: The amount of depression up to the maximum load (50 gf / cm ² ), which was determined by the following calculation formula.
To-Tm (mm)

Hereinafter, the present invention will be specifically described by way of examples.
Example 1
A beige pigment (beige masterbatch (1T90 manufactured by Dainichi Seika Kogyo Co., Ltd. )) was blended at a ratio of 0.54% by mass with polypropylene homopolymer (SA03 manufactured by Nippon Polychem Co., Ltd. (MFR 31 g / 10 min, melting point 164 ° C.)). a mixed resin, in a melt extruder this mixed resin, extrusion temperature 215 ° C., at a spinning temperature of 205 ° C., and the hole shape hole hole shaped flat (0.2 mm × 2.0 mm) (number of pores 120) Using a spinneret having a Y-shaped hole (number of holes 60), the yarn was discharged and spun at a spinning speed of 715 m / min.
Subsequently, the unstretched multifilament yarn obtained was subjected to simultaneous hot air crimping at a draw ratio of 1.9 times, a draw temperature of 100 ° C., a heat setting temperature of 125 ° C., and a hot air temperature of 175 ° C. without being wound once. Then, winding was performed at a crimp relaxation rate of 20.0% to obtain a polypropylene crimped yarn in which a flat section yarn of 2000 dtex 180 filament (hereinafter referred to as “f”) and a Y-type section yarn were mixed .
As shown in Table 1 , the obtained crimped yarn had a crimping rate of 7.8%, a flattening rate of the contained flat cross-sectional yarn of 6.5, and a bulk density of 9.3 (cm ³ / g). Further, the bulk density (cm ³ / g) of the flat cross-sectional yarn and the Y-shaped cross-sectional yarn constituting the crimped yarn were 7.1 and 14.0, respectively.
Using tufting machines 1/8 gauge the crimped yarn, pile driving density 12 yarns / inch, and tufted into the base fabric with pile height 8mm and pile and cut pile carpet cut pile. The passage through the tuft process was satisfactory without any particular problems. The cut pile carpet was polished to defiltrate the carpet surface pile . The resulting carpet was a cut-pile carpet with excellent nap, bulkiness and softness. Table 2 shows the physical properties of the carpet .

(Example 2)
The same polypropylene homopolymer as used in Example 1 was blended with an ivory color pigment (master batch for ivory (P591 manufactured by Dainichi Seika Kogyo Co., Ltd. )) at a ratio of 0.78% by mass, and the spinneret was flat (0 in spinneret of .2mm × 2.0mm) holes (hole number 60) and the hole shape Y-type hole (hole number 120), the hot air temperature during set to 0.99 ° C., addition was changed in example 1 In the same manner as above, a 2000 dtex 180f polypropylene crimped yarn was obtained. The physical properties of the obtained crimped yarn are shown in Table 1. Further, the bulk density (cm ³ / g) of the flat cross-sectional yarn and the Y-shaped cross-sectional yarn constituting the crimped yarn were 7.1 and 14.0, respectively.
A cut pile carpet was produced in the same manner as in Example 1 using the crimped yarn . The properties of the obtained carpet are shown in Table 2. The cut carpet was excellent in the ability to pass through the tufting process without any particular problems, and had excellent napping feeling, bulkiness and soft feeling.

(Comparative Example 1)
Except for using a spinneret having a Y-shaped hole (number of holes 180), a draw ratio of 2.2 times, and a crimp relaxation rate of 20.0 % , the same as in Example 1, A polypropylene crimped yarn of 2000 dtex 180f was obtained. The physical properties of the obtained crimped yarn are shown in Table 1. Using the obtained crimped yarn, an attempt was made to produce a cut pile carpet in the same manner as in Example 1. However , since the crimped yarn consists only of a Y-shaped cross-sectional yarn having a high bulk density , The pile could not be defibrated . The obtained carpet has physical properties as shown in Table 2. Although it was excellent in bulkiness, it was a cut pile carpet with a hard texture.

(Comparative Example 2)
Hole shape using a spinneret with a flat (0.2 mm × 2.0 mm) of the hole (hole number 180), 1.9 times the draw ratio, in addition to the crimp relaxation rate 15.4 percent, In the same manner as in Example 1 , a 2000 dtex 180f polypropylene crimped yarn was obtained. The physical properties of the obtained crimped yarn are shown in Table 1. A cut pile carpet was produced in the same manner as in Example 1 using the obtained crimped yarn . The resulting cut pile carpet was polished and the carpet surface pile was defibrated. The properties of the obtained carpet are shown in Table 2. The crimped carpet is a cut pile carpet that has excellent softness because the crimped yarn is composed only of a flat cross-sectional yarn having a low bulk density, but has no nap and bulkiness . .

It is a perspective view of the measuring instrument (sample stand) for evaluating the bulk density of the carpet obtained by the Example and comparative example of this invention. FIG.

Claims (2)

A pile having a cut pile that is composed of a polypropylene crimped yarn in which a polypropylene multifilament yarn (A) and a polypropylene multifilament yarn (B) satisfying the following conditions (1) to (3) are mixed. A polypropylene pile product that satisfies the following conditions (4) to (6):
(1) Polypropylene multifilament yarn (A) is the bulk density 11 ^(cm 3 / g) following polypropylene multifilament yarn
(The bulk density (cm ³ / g) was measured according to the method described in the specification.)
(2) commingled proportions of polypropylene multifilament yarn (B) is the bulk density 14 ^(cm 3 / g) or more polypropylene multifilament yarn (3) polypropylene multifilament yarn (A) and polypropylene multifilament yarn (B) Range of 1: 2 to 2: 1 (4) Work of compression (WC) ≧ 0.29 g · cm / cm ²
(5) Compression ratio (EMC) ≧ 18.5%
(6) Hardness of compression (LC) ≧ 0.70non The manufacturing method of a polypropylene pile product including the process of following (a)-(c) .
(A) The blend ratio of the polypropylene multifilament yarn having a bulk density of 11 (cm ³ / g) or less and the polypropylene multifilament yarn having a bulk density of 14 (cm ³ / g) or more is in the range of 1: 2 to 2: 1. the pile tufted commingled polypropylene crimped yarn
(B) Cut the pile
(C) Perform defibration processing