JPH0813315A - Wool tufted carpet - Google Patents

Abstract

PURPOSE:To produce a wool tufted carpet excellent in pencil point properties and bulkiness, reduced in idle hairs and resistive to change of visual appearance by applying a heat treatment to a spun yarn composed mainly of wool and containing blended binder fibers and using the resultant heat-treated yarn as a pile yarn. CONSTITUTION:With staple fibers composed mainly of wool subjected to yarn dyeing with a prescribed hue in advance, 2 to 20wt.% sheath-core type conjugated binder fiber composed of a high-melting polyamide having >=170 deg.C melting point as the core part and a low-melting polyester having <=130 deg.C melting point as the sheath part is subjected to blend spinning. A thermal adhesive treatment is applied to the resultant spun yarn by using a spell bar type continuous heat treatment machine to prepare a fused spun yarn. The obtained fused spun yarn is used as a pile yarn and a base fabric is tufted 19 to have a cut pile and/or loop pile state by using a tuft machine, thus producing the objective wool tufted carpet.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wool tufted carpet of good quality.

[0002]

2. Description of the Related Art It is known that a spun yarn mixed with binder fibers is used as a pile of a wool tufted carpet, and a heat treatment is performed to melt the binder fibers to fix the pile to produce a wool tufted carpet of good quality. And some suggestions have been made in the past. For example, JP-A-62-117869 and JP-A-2-84.
No. 520, Journal of the Textile Machinery Society (Vol. 47, No. 4, 1
0 to 18) and the like.

Here, a wool tufted carpet of good quality refers to a carpet improved in the following points. 1) Improvement of pencil point property: The fibers that make up the pile are not elastic but are in an elastic state when pressed. 2) Reduction of idle hair: Short fibers are difficult to come out when the carpet surface is rubbed. 3) Improvement of abrasion resistance 4) Bulkiness and less change in appearance It has been conventionally known that a polyamide fiber or a polyester fiber is used as the binder fiber for the purpose of the above improvement.

[0004]

Conventionally, polyamide-based binder fibers are good from the viewpoint of improving the quality of wool tufted carpets, but low-melting polyamides themselves are expensive and are not economically useful. It has been restricted. Although polyester-based binder fibers can improve the above-mentioned quality, the texture is hard and the best blend indication of wool (blending of wool and nylon 20% or less) is not possible because some fibrous polyester remains. There was an inconvenience.

The present invention is intended to solve the problems of the conventional wool tufted carpet containing binder fibers, and to economically provide a soft and good quality wool tufted carpet.

[0006]

As a result of intensive studies to solve the above problems, the present inventor has found that the problems can be solved by using a completely new type of binder fiber which has not been known. The present invention has been reached.

That is, the present invention relates to a wool tufted carpet having cut piles and / or loop piles, in which a high-melting point polyamide having a melting point of 170 ° C. or higher is arranged in the core part and a low melting point polyester having a melting point of 130 ° C. or lower is arranged in the sheath part. The core-sheath composite binder fiber and the short fiber mainly composed of wool, and the blending ratio of the binder fiber is 2 to 20% by weight.
In addition, the gist of the present invention is a wool tufted carpet characterized in that a pile is formed of spun yarn that is thermally fused with a binder fiber.

The present invention will be described in detail below.

The binder fiber used in the present invention has a core having a high melting point of polyamide having a melting point of 170 ° C. or higher and a sheath having a melting point of 130 ° C.
It is made of the following low melting point polyester.

The polyamide placed in the core of the binder fiber used in the present invention must have a melting point of 170 ° C. or higher.
Examples of such a polyamide include nylon 6 and nylon 66. If the melting point is less than 170 ° C,
Loss of fiber morphology due to high cost and heat fusion process,
This is inconvenient because the effect of sufficiently improving the quality may be lost.

As the low melting point polyester to be placed in the sheath portion, one having a melting point of 130 ° C. or lower, particularly polyethylene terephthalate, selected from isophthalic acid, sebacic acid, adipic acid, diethylene glycol, 1,4-butanediol or the like, or The thing which copolymerized two or more types of compounds is mentioned. Especially melting point 100-130 ° C
The polyethylene terephthalate / isophthalate copolymer is preferably inexpensive and easy to handle. If the melting point exceeds 130 ° C, the heat-bonding processing temperature becomes too high and the wool itself may deteriorate, which is not preferable.

Examples of the binder fiber include a core-sheath type and a sea-island type composite fiber in which a low melting point polyester forms a part to the entire surface of a single fiber in a round cross section or an irregular cross section. Of these, a composite fiber having a core-sheath type, a core of nylon 6, and a sheath of polyethylene terephthalate / isophthalate is preferable from the viewpoints of low cost, soft feeling, and high adhesive strength.

The fineness of the binder fiber is not particularly limited, but 2 to 20 denier is suitable.

The spun yarn used in the present invention has a core-sheath type binder fiber in an amount of 2 to 20 with respect to a short fiber mainly composed of wool.
Weight% is used. Binder fiber blend ratio is 2
If it is less than%, the effect of improving the quality by heat fusion is insufficient. Similarly, if the blended spinning rate exceeds 20%, the object of the present invention cannot be achieved after the heat fusion, which is too hard.

Wool is used as the main fiber, but 10
General-purpose nylon 6 and nylon 66 in a proportion of up to 20% by weight
Short fibers may be used together. In this case, further improvement in wear resistance can be expected.

The mixed spun yarn of binder fiber and wool may be any of the usual woolen type, worsted type, and semi-worsted type. In addition to the method of mixing the binder fiber and wool in the state of cotton, the sliver may be made of 100% binder fiber and then mixed with the wool sliver in the gil process or the like.

The heat-sealing process of the spun yarn used in the present invention may be carried out at any step from the spun yarn dyeing step to the heat treatment step of the backing agent of the carpet. The time treatment method is preferable because it can be sufficiently heat-sealed without deteriorating the wool.

The wool tufted carpet of the present invention uses a mixed spun yarn of binder fiber and wool as a pile yarn to form a cut pile and / or a loop pile by a tufting machine, and a dyeing step, backing step, backing It can be obtained through a heat treatment process of the agent.

[0019]

The binder fiber used in the wool tufted carpet of the present invention has a melting point of the core component higher than that of the sheath component by 40 ° C. or more, and only the sheath component is heat-sealed to leave the polyamide of the core component in a fibrous form. is there. In this case, the abrasion resistance is improved by the action of the polyamide remaining in the fibrous state, and the melting point of the melted low-melting polyester improves the pencil point property, prevents play hair, and improves the quality such as the difficulty of changing the appearance. Appears.

[0020]

The present invention will be described in detail below with reference to examples, but the present invention is not limited thereto. The evaluation methods for various physical properties described in the examples are as follows.

(1) Melting Point The melting point of a polymer having a crystalline melting point was measured by a DSC method using a differential scanning calorimeter DSC-2 type manufactured by Perkin Elmer Co. at a temperature rising rate of 20 ° C./min.

The melting point of an amorphous polymer having no crystalline melting point by the DSC method was measured by visual observation using a microscope with a hot stage. Unless otherwise noted, melting points are by DSC method.

(2) Pencil point property Ten panelists evaluated the product in the following three grades by a sensory test by holding a wool tuft carpet with their palms.

1: Moderately good 2: Normal 3: Insufficient pencil point 0: Too hard and poor (3) Abrasion resistance, difficulty in changing appearance Appearance of 70 ° C at one place on wool tufted carpet 2 hot water
Drip 0 cc and immediately rub it ten times with a nylon cloth,
Then, observe the degree of fiber dispersion in the tufts,
The grade was evaluated.

1: Good with little change 2: Normal
3: Remarkably bad change Example 1 Nylon 6 chip (melting point 215 ° C.) and polyethylene terephthalate / isophthalate copolyester (melting point 110 ° C. by visual inspection, terephthalic acid / isophthalic acid molar ratio 6/4) were depressurized. Dried. After that, it is melted by using an ordinary composite melt-spinning device, nylon 6 is arranged in the core portion, and polyethylene terephthalate / isophthalate copolymerized polyester is arranged in the sheath portion, and the composite ratio (weight ratio) is set to 1: 1 and spinning is performed. Temperature 260 ° C, total discharge 410g
/ Minute and the composite melt spinning was performed. The spun yarn was cooled and then taken off at a take-off speed of 1000 m / min to obtain an undrawn fiber yarn.

The obtained yarns were bundled, made into a tow of 100,000 denier, drawn at a draw ratio of 3.5 and a draw temperature of 60 ° C., and crimped using a push-in type crimper.
It was cut into a length of 51 mm to obtain a core-sheath type composite binder fiber having a single yarn fineness of 4 denier.

The obtained binder fiber, nylon 6 fiber (4 denier, 51 mm cut length) and New Zealand crossbread wool in a weight ratio of 10:10:80 (nylon and wool are beige dyed). Number of twists:
A spun yarn of s160 / z230 and a count of 2 / 4.0 Nm was obtained.

The obtained spun yarn was heat-bonded at 130 ° C. for 30 seconds by a continuous heat treatment machine of Superba. Use this thread, 1
/ 8 in. Gauge tufting machine pile height 10
Tufted to a cut pile carpet structure at mm, 305 stitches / m. Further, a latex backing containing a laminated secondary jute backing was used to obtain a wool tufted carpet having the cut pile of the present invention.

The obtained wool tufted carpet had a good pencil point property of 1, and had good abrasion resistance and resistance to appearance change of 1.

Examples 2 to 5 and Comparative Examples 1 to 2 Example 1 was repeated except that the blending ratio of the binder fiber used in Example 1 was changed. In addition, the increased and decreased amount of binder fiber was supplemented with wool. The results are shown in Table 1.
Shown in

[0031]

[Table 1]

As shown in Table 1, when the mixed spinning ratio of the binder fiber is 2 to 20% by weight, the result is good, but when the mixed spinning ratio is less than 2% by weight, a good quality product cannot be obtained.

On the other hand, if it exceeds 20% by weight, the pile becomes too hard, which is not preferable.

Example 6 Instead of the copolymerized polyester chip used in Example 1, a copolymerized polyester chip having a terephthalic acid / isophthalic acid molar ratio of 6.5 / 3.5 with a visual melting point of 125 ° C. was used. , Binder fiber and wool 10:90
And the condition of the continuous heat treatment machine of Superba is 140 ° C,
The same procedure as in Example 1 was carried out except that the time was 30 seconds.

The resulting carpet had good pencil point properties of 1, abrasion resistance, and resistance to appearance change of 1 as well.

Comparative Example 3 Instead of the copolyester chip used in Example 1, a copolyester chip having a terephthalic acid / isophthalic acid molar ratio of 7.5 / 2.5 with a melting point of 160 ° C. by visual observation is used. Example 6 was carried out in the same manner as in Example 6 except that the conditions of the continuous heat treatment machine of Superba were 170 ° C. and 30 seconds.

Since the discoloration of wool in the spun yarn after the heat treatment was severe and the strength of the spun yarn was half that in Example 6, the carpet production was abandoned.

[0038]

EFFECTS OF THE INVENTION The wool tufted carpet of the present invention has a novel binder fiber in which the pile is heat-fused, so that the pencil point property is good, there is little idle hair, and the bulkiness and appearance hardly change and the abrasion resistance is high. It is possible to obtain a product with improved quality.

Claims (1)

[Claims] 1. A wool tufted carpet having cut piles and / or loop piles, wherein the core portion has a high melting point polyamide having a melting point of 170 ° C. or higher, and the sheath portion has a melting point of 130.
A spun yarn composed of a core-sheath composite binder fiber having a low-melting point polyester at a temperature of ℃ or below and a short fiber mainly composed of wool, having a blending ratio of the binder fiber of 2 to 20% by weight, and being thermally fused with the binder fiber. A wool tufted carpet characterized by having a pile formed in it.