JPS6146578B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing a pile rug that has a novel appearance due to its unique pile form.More specifically, the present invention relates to a method for manufacturing a pile rug that has a novel appearance due to its unique pile form. to generate snarls and creases in the yarn (produce bending points with large bending angles in the yarn), and then produce a pile fabric from the snarled yarn,
The present invention relates to a method for manufacturing a pile rug having a unique appearance by dry heat treating the fabric to develop snarls and folds and heat setting the fabric. In general, the consumption characteristics required for pile rugs include practical performance such as little wear and deterioration due to long-term use, no exposure of the base fabric when folded (so-called ground cracking phenomenon), and appropriate compressive elasticity. However, it is also true that visual performance such as the pile form or the appearance (design) of pile rugs has also been recognized as a consumer performance with high demands. In order to meet such demands, the industry has adopted methods of manufacturing pile rugs using, for example, yarns with a large degree of crimp. The pile rug is produced by employing the so-called knit-denit method, in which the threads are knitted into a knitted fabric, heat-set, unwound, and the unwound thread is wound up again into a cone or the like. However, with this method, the loop shape (folded) of the heat-set yarn
This leads to disadvantages such as the yarn being stretched due to the tension during winding, and the heat-setting effect being significantly reduced due to changes in the yarn over time during storage.In the end, the resulting product has exceptional commercial value. It didn't reach that point. Another method, as disclosed in Japanese Patent Publication No. 47-28440, has been adopted in which highly twisted yarn is tumbled to generate snarls and heat-set at the same time, and the thus obtained yarn is used to manufacture pile rugs. There is. However, all of the piles obtained by this method produce only bending points with small bending angles, and even if a rug is made from such piles, it is difficult to say that it can exhibit a particularly novel appearance. However, the present inventors conducted intensive research in order to improve the deficiencies of the above-mentioned conventional technology and create a pile rug that can exhibit a novel and unique appearance. It was discovered that by heat-setting, it is possible to impart bending points with large bending angles to the yarns, thereby producing pile rugs with excellent appearance specificity in which the pile tips are inclined in irregular directions.The present invention has been made. reached. The main object of the present invention is to propose an industrially advantageous method for manufacturing pile rugs having a unique surface appearance. Another object of the present invention is to provide a pile rug that has a novel appearance and is made of a pile material having a large bending angle and whose tips are inclined in an irregular direction, and has excellent resistance to settling. There is a particular thing. Still other objects of the present invention will become apparent from the detailed description provided below. Therefore, the object of the present invention is to use highly twisted yarns with a twist coefficient of 150 or more as raw yarns for pile formation when producing pile rugs, and to supply such highly twisted yarns into a continuous heat treatment cylinder in a moist heat atmosphere of 90°C or more. , after generating a snarl, it is allowed to stay in the folded state,
Forming a bending point with a large bending angle in the yarn and taking it out from the processing tube, then producing a pile fabric using the thus obtained treated yarn, and then subjecting the pile fabric to a dry heat treatment at 100°C or higher. This can be achieved by In the pile rug thus obtained, each pile constituting the rug has one to several bending points with large bending angles per pile length, and the tip is bent in various directions. The pile has a regular slope, and if the pile is a cut pile, it has the characteristic that it can maintain a focused state (so-called vensil point shape) without unraveling or unraveling of the pile tip.
Both cut pile and loop pile have a unique appearance not seen in conventional products, are free from cracking, and have improved resistance to settling, and are extremely valuable as products. Here, the pile-forming yarn used in the practice of the present invention is generally not subject to any particular restrictions as long as it can be used in the production of pile products, and general-purpose natural fibers, synthetic fibers, etc. may be used alone or in combination. It can be used. In particular, synthetic fibers include nylon, polyester, and acrylic fibers, and the object of the present invention can be advantageously achieved by using acrylic fibers. Further, it is essential that the pile-forming spun yarn be selected and used from those having a double-twisted yarn or a twisted yarn of double-twisted yarn or more, and a ply twist coefficient of 150 or more, preferably 180 or more. In other words, when using a spun yarn with a twist coefficient of less than 150, it is difficult to make the yarn have a bending point with a large bending angle even if it is introduced into a continuous heat treatment device described below and subjected to heat treatment. This makes it difficult to produce pile rugs with a unique appearance. Regarding the shrinkability of the spun yarn, both latent heat-shrinkable and non-shrinkable yarns are applicable, but in order to effectively achieve the purpose of the present invention, latent heat-shrinkable yarn is adopted. is preferable. Incidentally, the preferred shrinkage rate range is 20 to 30%. Thus, the spun yarn for pile formation after this is
It is supplied to a continuous heat treatment apparatus equipped with a treatment cylinder having an appropriate diameter. Such continuous heat treatment equipment is
This is a heat treatment device equipped with a processing cylinder having an appropriate diameter (usually 40 to 70 mm), and is capable of performing moist heat treatment by allowing the yarn to remain folded in the processing cylinder for a certain period of time. It is commercially available as a Hakoba-type continuous valve device, etc. The manner of use of such a continuous heat treatment apparatus is explained as follows. That is, when the above-mentioned highly twisted yarn is continuously fed into the processing cylinder, torque is generated by heating and tensionless action during the process of the yarn falling through the processing cylinder, and the yarn reaches the folding position within the processing cylinder. At the same time, the tension in the yarn is released and the yarn remains in a relaxed state, so that snarls and folds occur due to the torque, forming a bending point. Such bending points are characterized by extremely large bending angles and by maintaining the potential to easily restore the original shape by applying appropriate heat treatment even if temporarily stretched. Moreover, since this phenomenon occurs continuously in the pile forming yarns that are continuously supplied, the spacing between the snarls can be maintained at 2 to 10 mm. In addition, the heat treatment using such continuous heat treatment equipment is 90%
It is necessary to carry out the process at a temperature of ℃ or higher. That is, if the treatment temperature is lower than 90° C., the generation of snarls will be insufficient and it will be difficult to form bending points with large bending angles in the treated yarn, which is not preferable. On the other hand, when a discontinuous heat treatment device (device related to the batch method) is used to perform moist heat treatment on spun yarn for pile formation, only a small number of bending points with large bending angles are observed in the treated yarn. Naturally, even if pile rugs are produced using such treated yarns, it will not be possible to impart a unique appearance. Incidentally, in order to clarify the difference in bending shape between the treated yarn related to the continuous heat treatment device and the treated tube yarn related to the discontinuous heat treatment device, explanation will be made using FIGS. 1 and 2. Figure 1 is a model diagram of the yarn for pile formation collected at the exit end of the treatment tube after a spun yarn with a twist coefficient of 240 was subjected to moist heat treatment for 50 seconds in a continuous heat treatment device (Hakoba type; 100℃), and Figure 2 The spun yarn (skelet type) with a ply twist coefficient of 40 is placed in an autoclave container (100
FIG. 3 is a model diagram of a pile-forming yarn after being subjected to a moist heat treatment at ℃) for 10 minutes. As shown in FIG. 1, the yarn produced by the treatment method of the present invention has bending points with large bending angles at relatively short intervals, while FIG. It can be clearly seen that there are very few bending points with a loose coil shape and a large bending angle. The continuously heat-treated pile-forming yarn moves in a folded mass inside an inclined tray attached to the exit end of the processing cylinder, begins to unravel near the tray exit, and is further wound up into a cone. In such a case, if the yarn is cooled to 60°C or less before unraveling, it is preferable that the dry heat treatment after producing the pile fabric can give the pile a bent shape with a large bending angle (making it easier to restore). . Subsequently, the cone-up spun yarn is made into a pile fabric using an ordinary tufting machine or the like. However, it is necessary to subject the pile fabric obtained after the levering to a dry heat treatment. In other words, the bent shape imparted to the yarn is once stretched due to tension during cone up, but it is restored again by this dry heat treatment, and each pile reappears with one or several bending points with large bending angles. This is because it becomes possible to obtain the desired result. The temperature range that can be employed in such dry heat treatment must be 100°C or higher, preferably 110°C or higher. That is, if the temperature is less than 100°C, it will be difficult to restore the bending point with a large bending angle to the pile, which is not preferable. Note that the upper limit of the dry heat treatment temperature is desirably limited to 150° C. in consideration of thermal decomposition of the raw material fibers and dyes used.
Although the present inventors have not fully investigated the reason why the bent shape of the yarn is restored in this way, it is likely that the bent shape of the yarn according to the present invention is not simply bent, but is strongly twisted. Since this is a part of the snarl caused by the torque of the yarn, it is presumed that this is because the yarn has a high degree of restoring force built into it. As mentioned above, the pile rug according to the present invention can only be produced by integrally combining the selection of the starting material, the unique continuous heat treatment of the material, and the dry heat treatment of the pile fabric produced under these conditions. It is clear that due to the uniqueness of its external shape, it can greatly contribute to future product development. Examples will be described below to better explain the present invention, but the scope of the present invention is not limited thereby. Example 1 Acrylic synthetic fiber 15 denier x 114 mm 40% by weight as dyed raw cotton, acrylic composite fiber 10 denier x 102 mm 30% by weight, 6 denier acrylic shrinkable fiber with fiber shrinkage rate 20%
102mm (all made by Japan Exlan Kogyo) 30% by weight, spun yarn (pile forming yarn) with a spinning count of 2 to 6.3 ^S (metric count), a first twist coefficient of 80, and a second twist coefficient of 240 is semi-spun. Produced by worsted spinning method.
The spun yarn thus produced was fed to a continuous heat treatment device Balcon (manufactured by Sakamoto Rensen Kagaku, Takahashi Electric Industry Co., Ltd.) having a treatment tube with an inner diameter of 60 mm, and the temperature was 100°C and the residence time was
The yarn is subjected to moist heat treatment for 50 seconds, and then guided in a lump form into a tray connected to the exit end of the treatment tube, and while being moved into the tray, the temperature of the yarn is controlled using a cold air fan.
It was cooled to 50-55°C and then rolled up into a cone while unrolling. The yarn treated in this manner is fed to a 5/32G tufting machine, and cut pile and loop pile are vegetated on the base fabric (cotton fabric) with stitches of 6st/in, pile length of 15mm, and area weight of 1.0Kg/ ^m2 . Two types of pile fabrics were prepared, and then a packing resin was applied to the back side of each fabric, and both were subjected to a dry heat treatment at 120°C for 15 minutes for drying. Of the two types of rugs obtained in this way, the cut pile rug has all the pile tips gathered together without being separated, forming a good pencil point shape, and each pile is
On the other hand, loop pile rugs have small snarls in most of the piles, and both cut pile and loop pile have pile tips that are irregular in various directions. A pile rug that has a unique pile shape not found in conventional products that have fallen down, has a special appearance on the entire rug surface, is highly elastic, and has no so-called ground cracks and has outstanding commercial value. It was hot. The yarn shrinkage rate of the yarn used in this example was 25% in continuous moist heat treatment. Example 2 Using the same spun raw cotton as in Example 1, the twist coefficient was
Three types of spun yarns were produced in the same manner as in Example 1 except that the yarns were 200, 170, and 140. These three types of spun yarns were subjected to the same moist heat treatment as in Example 1,
Three types of cut pile rugs were produced in exactly the same manner as in Example 1. As a result of evaluating the pile rug thus obtained,
A pile rug made using a yarn with a twist coefficient of 200 was as good as that obtained in Example 1, and a pile rug made using a yarn with a twist coefficient of 170 had a lower bending point. Although some piles with small bending angles were observed, overall it was an excellent pile rug similar to that obtained in Example 1. On the other hand, in a pile rug made using yarn with a ply twist coefficient of 140, although the tip of the pile forms a pencil point shape, there are almost no bending points with large bending angles, so the pile has a peculiar shape. It had no shape, and it was difficult to recognize that it was a particularly special pile rug compared to conventional products. From this result, it will be understood that the pile rug targeted by the present invention can be produced only by using yarn having a ply twist coefficient within a predetermined range. Example 3 The same spun yarn as used in Example 1 was fed to the continuous heat treatment device Balcon used in Example 1, and the same treatment as in Example 1 was carried out except that the wet heat treatment temperature was set to 80°C and 120°C. Two types of treated yarns were obtained. Two types of cut pile rugs were produced in exactly the same manner as in Example 1 using each of these yarns. However, the pile rug made using yarn treated with moist heat at 80°C not only had an extremely imperfect pencil point shape, but also had problems with the pile. No bending points with large bending angles were observed, and the product had no characteristics compared to conventional products. Example 4 Instead of using acrylic shrinkable fibers with a fiber shrinkage rate of 20% in Example 1 as dyed spinning raw cotton, (i) acrylic shrinkage fibers with a fiber shrinkage rate of 18% 6 denier x 102 mm, (ii) Acrylic shrinkable fiber 6 denier with fiber shrinkage rate of 12%
102mm, (iii) Ordinary acrylic fiber (non-shrinkable) 6
Denier x 102mm (all manufactured by Nippon Exlan Kogyo) was used at 30% by weight, and the rest was Example 1.
Three types of spun yarns (i), (ii), and (iii) were prepared by mixing the same raw cotton as used in 2018, with a ply twist coefficient of 240, and changing the spinning yarn count as shown in Table 1.
was created. These spun yarns were subjected to continuous moist heat treatment in exactly the same manner as in Example 1, and the resulting treated yarn 5/
The yarn was fed to a 32G tufting machine, and three types of cut pile fabrics were produced according to the tufting conditions listed in Table 1.
Next, it is subjected to backing treatment and dried at 120°C.
Dry heat treatment was carried out at
In addition to the treatment temperatures of 80°C and 160°C for comparison, a total of 5 types of pile rugs were produced.
Table 1 also shows the evaluation results of the thus obtained pile rugs in terms of the bent shape of the pile, the pencil point shape of the pile tip, the overall appearance of the surface, and the degree of thermal discoloration. Incidentally, the shrinkage rate that occurred in the yarn due to the continuous moist heat treatment in this example was 22% in the case of the spun yarn (i) and 15% in the case of the spun yarn (ii).

[Table] Comparative Example 1 A spun yarn similar to that used in Example 1 was placed in a closed container in the form of a skein, and heated at 100°C for 10 minutes by blowing live steam into it.
A moist heat treatment was performed for a minute. Most of the wet heat-treated yarn thus obtained had a loose coil shape, and only a few bending points with large bending angles were observed. Although cut pile rugs made using such yarns have slight curvature or inclination in the pile, there are almost no piles that have bending points with large bending angles, which is the object of the present invention, and the surface appearance is also particularly special. It could not be recognized as a thing. From this result, it can be understood that in order to achieve the object of the present invention, it is important to treat the yarn using a continuous moist heat treatment apparatus such as a continuous heat treatment apparatus.

[Brief explanation of the drawing]

Figure 1 is a model diagram of a highly twisted yarn subjected to wet heat treatment using a continuous heat treatment device and taken from the exit end of the treatment tube. Figure 2 is a model diagram of a highly twisted yarn subjected to wet heat treatment using a discontinuous heat treatment device. FIG. 3 is a model diagram of a later treated yarn.

Claims (1)

[Claims] 1. When producing a pile rug, a highly twisted yarn with a twist coefficient of 150 or more is used as the raw yarn for pile formation, and the highly twisted yarn is fed into a continuous heat treatment cylinder in a moist heat atmosphere of 90°C or more to generate snarls. The yarn is allowed to stay in the folded state to form a bending point with a large bending angle, and then taken out from the processing tube.The treated yarn thus obtained is then used to produce a pile fabric, and then the pile fabric is A method for producing a pile rug with a special appearance characterized by dry heat treatment at temperatures above ℃.