JPS6144980B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a cut pile rug having an irregular pattern, and more specifically, the present invention relates to a method for producing a cut pile rug having an irregular pattern, and more specifically, a method for producing a cut pile rug having an irregular pattern. A pile fabric is produced using yarn, and then the fabric is subjected to a dry heat treatment. Despite using only one type of yarn for forming pile yarn, the surface of the pile fabric is coated with various shapes based on the specificity of the pile shape. The present invention relates to a method for manufacturing pile rugs in which irregular patterns are formed using a variety of materials.

In general, as for the consumption performance required of pile rugs (carpets, etc.), it goes without saying that maintenance of practical performance, such as less wear and tear when used for a long period of time, is important. On the other hand, it is a well-known fact that the aesthetic performance of appearance, such as pile form and surface form, is also widely recognized as being highly demanding. It is also true that, especially in recent years, with the increasing demand for pile rugs, there has been a wide demand for pile products that have an ever-new appearance. In response to these demands, various pattern patterns have been formed using combinations of cut pile and loop pile (cut and loop), combinations of two types of piles with different pile lengths (high and low), etc. Products that can give characteristics to the surface morphology of pile rugs have been provided, but those that can be made using conventional pile product manufacturing technology are ones that are entirely made of loop piles and have a uniform pile length;
It is almost limited to those that are entirely made of loop pile and have different pile lengths, those that are a combination of long pile length cut pile and short pile length loop pile, and those that are entirely made of cut pile and have uniform pile length. In addition to this, products have been proposed, for example, products that are made only of cut pile and have patterns formed by varying the length of the pile, but they have no choice but to use a method of making cuts by hand in the pile. Naturally, it was limited to special luxury items.

The present inventors broke through the limitations of such conventional technology,
As a result of extensive research in order to produce pile rugs that have a progressively new appearance that could not be produced using conventional industrial methods and are also highly resistant to sagging, we have developed a raw yarn for forming pile yarns. A cut pile fabric is produced using yarn that has been subjected to moist heat treatment to give a partial and irregular repeating period and length, and the resulting fabric is dry heat treated at a specific temperature. The pile yarn section that has been subjected to moist heat treatment has a stick-like pile shape (hereinafter referred to as pencil point shape) in which the tip end is neither untwisted nor defibrated.
On the other hand, the untreated portion of the pile yarn becomes a normal cut pile (so-called plastic type) in which the tip of the pile is defibrated.
The present invention was achieved by discovering that in pile fabrics made of different types of piles, each of the piles forms individual clusters (pile groups), and that the clusters intersect randomly to create a special pattern. .

The main object of the present invention is to use only one type of pile yarn-forming raw yarn and to use an ordinary pile fabric manufacturing device to produce fabrics with an irregular pattern and excellent resistance to sagging. The object of the present invention is to propose a method by which completely new cut pile rugs can be produced industrially and advantageously.

Another main object of the present invention is to provide a cut pile rug that has a unique pattern and is highly resistant to sagging.

Furthermore, other different objects of the present invention will become apparent from the following description.

Thus, the object of the present invention is to subject raw yarn for forming pile yarn to a partial moist heat treatment at 90° C. or higher in order to give it a partial and irregular repetition period and length, and to produce treated yarn obtained in this way. This can be effectively achieved by producing a cut pile fabric using strips and then subjecting the fabric to dry heat treatment.

The cut pile rug produced in this way has two parts: a part consisting of a bunch of pencil point-shaped piles (hereinafter referred to as Saxony type) in which the end part of the pile has not been untwisted or defibrated; 2. A plastic type part consisting of piles that are untwisted and opened.
It consists of small settlements (pile groups) each having a different pile structure, and these are mixed together irregularly, forming an irregular and repeating pattern with no regularity, giving it a unique appearance. In addition, the pile exhibiting a pencil point shape has an appearance similar to a loop pile when viewed at a glance, so when looking at the entire surface of the fabric, it has an appearance similar to an irregular cut-and-loop. Since the pile structure cannot be easily produced, the surface morphology of the pile rug produced according to the method of the present invention can give a significantly new (so-called novelty) feel. Furthermore, since the pile with a pencil point shape maintains the twisted shape of its tips, it is less likely to collapse compared to piles whose tips have been loosened, so it has good practical properties (settling resistance, etc.). It is possible to provide a pile rug that is excellent and can be used in a wide range of areas and has extremely high commercial value.

In carrying out the present invention, it is possible to use both yarns that have latent heat shrinkability and yarns that do not have latent heat shrinkability as the yarn for forming pile yarns. Even when yarn is used, it is possible to produce a pile rug with an irregular pattern. In addition, the apparent difference in pile rugs caused by the presence or absence of latent heat shrinkage is that when using shrinkable yarns, a high and low structure can be created, while when using non-shrinkable yarns, the pile length can be reduced. They are suitable for producing a uniform (plain-cut) pile structure, and both can provide a sense of gradual innovation.

The fiber material constituting the yarn for forming the pile yarn can be arbitrarily selected from ordinary acrylic fibers, etc. If shrinkable fiber is used, it has a potential heat shrinkage of 15% or more. It is preferable to select and use acrylic synthetic fibers having a Composite fibers can also be used as one of the constituent fiber materials, and it is particularly preferable that the constituent fibers of the non-shrinkable yarn contain conjugate fibers in an amount of 20 to 80% by weight based on the total constituent fibers. Furthermore, in any case, the raw yarn as a starting material must be highly twisted (twisting coefficient of 120 or more).

Here, in carrying out the present invention, when using either a latent heat-shrinkable yarn or a non-shrinkable yarn, the yarn for the pile yarn must be partially subjected to moist heat treatment prior to knitting or weaving the pile fabric. is necessary.
Regarding such partial moist heat treatment, there are no particular restrictions as long as the treated and untreated portions of the yarn are distributed mutually and while maintaining appropriate lengths, but if a series of treated or untreated portions are The length of the treated portion is preferably 3 cm or more and 50 cm or less, and the weight ratio of the treated portion to the untreated portion in the total amount of yarn is preferably within the range of 20/80 to 80/20.

In addition, an embodiment of the partial moist heat treatment of the yarn for forming pile yarn will be described below. Any method may be used to subject the yarn to partial moist heat treatment as long as the treated portions and untreated portions are mixed irregularly, and examples of preferred embodiments include (i) ) Place the yarn to be treated in the form of a skein on a plate-like object having countless pores through which steam can pass, or on a net-like object such as a wire gauze of an appropriate density, with the yarns in the skein being as parallel and uniform as possible. On the other hand, a circular, rectangular or other shaped steam outlet with a size that can cover the entire width of the skein is attached to the tip of the bendable steam pile, and one such outlet is installed. Or a means of placing several skeins on top of the skeins to blow out steam (by adopting such a means, the steam hits only the skein portion covered by the spout and penetrates between the skeins, and also passes through the rear perforated plate or net-like material) (and thus partial moist heat treatment of the skein is achieved)
Or (ii) Using a skein dyeing machine or a device that applies steam heat treatment to yarn, insert only a portion of the skein to be treated into the device, and perform partial treatment by injecting steam into the device. means. Alternatively, (iii) means for partially covering the skein with a cloth, sheet, or film that does not easily conduct heat, and then injecting steam to treat only the exposed portion with moist heat. Furthermore, (iv) there is a means for performing partial interruption treatment by intermittently injecting steam to the running yarn from the side, top, or bottom when winding the yarn into a cone; The heat treatment time varies slightly depending on the treatment method, but when the yarn is left to stand still for treatment, it is preferable to continue spraying steam for one minute or more.

In addition, the temperature conditions for such moist heat treatment will be described. First, when using a yarn that does not have latent heat shrinkability as the yarn for forming pile yarn, it is necessary to set the moist heat treatment temperature to 90° C. or higher. The yarn portion treated with moist heat at a temperature higher than the normally used twist-setting temperature will be firmly twisted and set, and may become a Saxony-like portion in the pile rug structure. If the wet heat treatment temperature is less than 90℃, the effect of twist setting will be insufficient, and the pile tips will untwist or fibrillate during the dry heat treatment performed after knitting and weaving the pile fabric, making it difficult to maintain the pencil point shape. becomes.
Furthermore, in order to maintain a good pencil point shape, it is more preferable to set the moist heat treatment temperature to 100° C. or higher.

On the other hand, even when yarn with latent heat shrinkability is used as the yarn for forming pile yarn, the temperature of the moist heat treatment must be set at 90°C or higher, and the yarn that has been subjected to such moist heat treatment must be The portion is not only twisted and set, but also as shrinkage occurs, the twist coefficient increases and the intertwining between single fibers is strengthened, making it easier to form pencil points.
In order to fully exhibit the shrinkage of the yarn and the effects associated with the shrinkage, it is more preferable that the wet heat treatment temperature is 100° C. or higher.

The pile yarn that has been partially subjected to the moist heat treatment is then knitted into a cut pile fabric using a conventional cut pile production means such as a tufting machine, and then it is necessary to subject the fabric to a dry heat treatment. Suitable temperature conditions to be adopted during dry heat treatment are 60°C or higher when non-shrinkable yarn is used as the pile yarn-forming yarn, while 110°C or higher when latent heat-shrinkable yarn is used. preferable. If the dry heat treatment is not performed, no matter which yarn is used, the tip of the pile, which should form a defibrated pile form, is difficult to untwist or unravel, making it impossible to achieve the object of the present invention. In addition, the dry heat treatment temperature
When the temperature exceeds 140℃, no matter which yarn is used, untwisting or fibrillation occurs at the tip of the pile that should form a pencil point shape, and a pattern pattern based on the difference between the two types of pile forms becomes apparent. should be avoided as it will be difficult. In addition, using a yarn having latent heat shrinkability as the raw yarn for forming the pile yarn,
When producing a pile rug according to the method of the present invention, the yarn portions that have not been subjected to moist heat treatment before knitting and weaving of the pile fabric are subjected to dry heat treatment (at 110°C) after knitting and weaving the pile fabric.
As a result, the pile length is shortened compared to the Saxony type pile, forming a high-and-low structure. Such high-and-low carpets are constructed only from cut piles, and cannot be easily produced using conventional pile rug construction techniques, so they also have a completely new appearance in terms of surface morphology.

Furthermore, in the practice of the present invention, the dry heat treatment performed after producing the pile fabric can also be performed as a drying step in the packing treatment.

Furthermore, generally in the finishing process of cut pile rugs, shearing treatment is sometimes performed to align the tips of the piles, but such treatment is not excluded in the practice of the present invention. That is, in the present invention, shearing treatment may be performed or not,
There are no particular restrictions on the order of the shearing process, but when using latent heat-shrinkable yarn as the yarn for pile yarn formation, the shearing process should be carried out prior to the dry heat treatment or not at all. If not carried out, a pile rug with a high and low structure is obtained. In addition, if non-shrinkable yarn is used as the yarn for forming pile yarn, a pile rug with a uniform pile length can be obtained, but if shearing treatment is performed before or after drying treatment, the surface morphology of the pile fabric will become even more beautiful. .

In order to better recognize the pile form of the pile rug obtained according to the method of the present invention, the first
This will be explained using FIGS.

Figures 1 to 4 are schematic diagrams showing pile side cross sections, and Figure 1 shows the pile fabric after knitting and weaving using latent heat-shrinkable yarn, and the partial view before the pile fabric knitting and weaving. It consists of a pile 1 formed from a portion where the yarn count has increased due to shrinkage due to moist heat treatment, and a pile 2 formed from a yarn portion that has not undergone the moist heat treatment, and the tip of the pile 2 is made of pile fabric. Even immediately after the fibers are defibrated to some extent. Figure 2 shows the pile fabric after knitting and weaving when non-shrinkable yarn is used, and shows the pile 3 formed from the yarn portion twisted and set by partial moist heat treatment before knitting and weaving the pile fabric, and the heat treatment. It consists of a pile 2 formed from the unsupported part.
Figure 3 shows the pile fabric shown in Figure 1 which has been subjected to dry heat treatment, and consists of pile 4, which maintains its pencil point shape despite the dry heat treatment, and pile 5, which has shrunk due to the treatment. , Pile 5 shows a state in which the pile tip is defibrated with the onset of contraction. In addition, Fig. 4 shows the pile fabric shown in Fig. 2 which has been subjected to dry heat treatment, and consists of a pile 4 that maintains a pencil point shape and a pile 6 whose tip has been defibrated by the treatment, and the pile length is approximately It shows a state that is maintained uniformly.

Examples will be described below in order to better understand the present invention, but the present invention is not limited thereby.

Example 1 Acrylic synthetic fiber dyed with cotton as raw material fiber
15 denier x 114mm 30% by weight, 10 denier x 114mm
40% by weight and latent heat shrinkage (fiber shrinkage rate: 32% when treated in boiling water for 10 minutes) acrylic synthetic fiber 5 denier Spinning count 2/4′ ^S (metric count), number of twists 260T/M,
A spun yarn with a twist number of 230T/M (twist coefficient 165) was produced. Using such spun yarn, the circumference is 2m and the skein weight is 250.
A skein of g was made. The shrinkage rate of the yarn thus obtained was approximately 40%.

The thus obtained skeins were placed on a wire mesh with the threads aligned parallel to each other, and two bendable steam pipes with approximately square nozzles each measuring 25 cm on a side were attached to the ends. Nozzles were placed on the skeins at intervals of about 20 cm, steam was jetted out at 100° C. for about 1 minute, and only the portion covered by the nozzles was subjected to moist heat treatment. In the partially heat-shrinkable yarn thus obtained, the weight ratio of the treated portion to the untreated portion was approximately 50/50, and shrinkage occurred only in the treated portion, resulting in an increase in the apparent diameter and twist modulus of the yarn. Ta. The yarn was wound into a cone, and then fed to a 5/32G tufting machine to produce a cut pile fabric under conditions of stitches of 8 ST/in and pile length of 8 mm. Next, a packing resin was applied to the back surface, and a dry heat treatment was performed at 130° C. for 10 minutes, which also served as drying.

The cut pile rug thus obtained is formed from small clusters of two types of piles: a pile that maintains a tightly clustered pencil point shape with no untwisted pile tips, and a plastic type pile with well-untwisted pile tips. The pile length of the plastic type part is 2 to 3 mm lower than that of the Saxony type part, forming a high and low pattern. It was an excellent pile rug with a unique and innovative form. In addition, the Saxony type part was less likely to sag due to an increase in the ply twist coefficient of the pile yarn, and was a product with excellent practical characteristics.

Comparative Example 1 A skein similar to that used in Example 1 was subjected to partial moist heat treatment using the same method as in Example 1, except that the partial moist heat treatment temperature was changed to 80°C. A pile rug was made using the same method. In the cut pile rug thus obtained, there are almost no piles in which the pile tip maintains a pencil point shape, so no saxony-shaped part is formed, and the pile that forms a plassy-shaped part is a solution of the pile tip. The twisting and fibrillation conditions were insufficient, and not only were there no patterns observed on the surface of the rug, but the pile length was uneven, and the product had no commercial value as a pile rug.

Comparative Example 2 The same fiber as used in Example 1 was spun by semi-worsted spinning with a count of 2/4S (metric count), number of lower twists of 260T/M, number of upper twists of 150T/M (twist coefficient 106).
A spun yarn was produced.

A skein similar to that in Example 1 was produced using such a spun yarn, and heat treatment and tufting were performed in the same manner and under the same conditions as in Example 1.

In the cut pile rug thus obtained, the pile tips were untwisted throughout, and a pile rug with a special appearance like that of Example 1 could not be obtained, and the pile threads had a large degree of settling.

Example 2 Acrylic synthetic fiber 15 dyed as raw material cotton
Denier x 114mm, 6 denier x 89mm, and acrylic composite fiber 10 denier x 114mm (all manufactured by Nippon Exlan Kogyo) are mixed at a ratio of 30, 30, and 40% by weight, respectively, and spun using a semi-worsted spinning machine with a thread count of 3/3.
5.S (metric count), the number of first twists is 300T/M, and the number of first twists is 200T/M (twist coefficient 154).

The thus obtained skein was partially subjected to moist heat treatment in the same manner as in Example 1, and a cut pile fabric was prepared using a 5/32G tufting machine at a stitch rate of 8 ST/in and a pile length of 8 mm. Next, in the same manner as in Example 1, 130
Dry heat treatment was performed at ℃ for 10 minutes.

The cut pile rug obtained according to the method of the present invention has a uniform pile length and is formed from small clusters of Saxony type portions and plassy type portions, and the pencil point-shaped pile tip is slightly separated. A slightly twisted pile was also observed, but even though the pile length was the same as that of the plastic type pile, it was easily distinguishable at a glance, and a random pattern was observed on the entire surface of the pile rug, which seemed to be a novelty. It was a pile rug with an excellent appearance.

Furthermore, when the pile rug obtained here was further subjected to shearing treatment, the pattern was not impaired in any way and the uniformity of the pile length was increased, resulting in an even more beautiful appearance.

Example 3 Among the raw material fibers used in Example 1, as the potentially heat-shrinkable fibers, (i) 30% by weight of acrylic synthetic fiber with a fiber shrinkage rate of 17% was used, and (ii) a fiber shrinkage rate of 12 % of acrylic synthetic fibers (all manufactured by Nippon Exlan Kogyo), the other raw material fibers used were the same raw material fibers as in Example 1, and the same procedure as in Example 1 was carried out (i). (ii)2
We made different types of cut pile rugs.

Among the cut pile rugs obtained in this way, the pile rug (i) in which fibers with a shrinkage rate of 17% were mixed as potential heat-shrinkable fibers maintained a tightly clustered pencil point shape with the pile tips not being untwisted at all. It consists of piles and plassy-type piles with open pile tips, each forming small settlements, and these small settlements intermingle to form an irregular pattern. The pile rug had a high and low structure with a pile length 1 to 2 mm longer than the pile in the plastic type part, and was an excellent pile rug. It also has a shrinkage rate of 12% as a potentially heat-shrinkable fiber.
Pile rugs (ii) that use a mixture of fibers include a pencil point-shaped pile with a relatively well-organized pile tip, a plastic pile with a defibrated tip, and a pile with a slightly pointed pile similar to a pencil point shape. A few poorly organized piles were observed, but when observed overall, an irregular pattern was formed in which small clusters of pencil point-shaped piles and small clusters of plassy-type piles intermingled with each other. It was a cut pile rug with a unique appearance and a commercial value.

In this example, the shrinkage rate of the pile yarn-forming yarn used for the pile rug (i) was 22%, and that for the pile rug (ii) was 16%.

[Brief explanation of the drawing]

Figures 1 to 4 are all schematic diagrams showing the cross section of the pile side of the pile rug, and Figures 1 and 3 show the use of a latent heat-shrinkable yarn as the yarn for forming the pile yarn; The figure and FIG. 4 show the pile form when non-shrinkable yarn is used. Further, FIGS. 1 and 2 show the pile form before the dry heat treatment, and FIGS. 3 and 4 show the pile form after the dry heat treatment. 1, 3: Parts subjected to partial moist heat treatment before knitting of pile fabric. 2: Unprocessed part. 5: Pile shrunk by dry heat treatment after knitting and weaving the pile fabric.

Claims (1)

[Claims] 1 Highly twisted raw yarn for forming pile yarn with a twist coefficient of 120 or more is subjected to partial moist heat treatment at 90°C or higher in order to give it a partial and irregular repetition period and length, and the treatment obtained in this way A cut pile fabric is made using the yarn, and then the fabric is heated to 60℃~
A method for producing a cut pile rug having an irregular pattern, characterized in that pile groups having Saxony type and plastic type tip portions are mixed irregularly by dry heat treatment at 140°C.