A wool-like fiber used in carpets, etc.
Patent Information
- Application Number
- JP2024545756
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-02-02
- Filing Date
- 2022-03-29
- Publication Date
- 2025-09-24
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
[Technical field]
[0001] Technology Areas The present disclosure generally relates to a method and apparatus for producing and using a wool yarn replacement for floor covering applications such as carpeting. The present invention relates to a method for producing a multifilament fiber as a multifilament fiber. The present invention also relates to a wool-like yarn of the menthol, and to floor coverings made from said yarn. [Background technology]
[0002] 2. Background of the Invention Traditionally, wool has been used for carpeting due to its natural texture, softness, elasticity and thermal properties. It has been the most popular fiber for many years. It is also a natural material with a high wool content. The structure is also a reason for its popularity. However, in recent times, wool has lost its most favored position in the flooring industry due to its main shortcomings: Lost. 1) The use of wool was discontinued because wool must be harvested by shearing animals such as sheep. There is an increasing number of animal welfare activists who are trying to reduce or eliminate animal cruelty. 2) The length of wool fibers generally used for flooring is 60 to 200 mm, so wool fibers ( The lint from the yarn can shed and cause respiratory problems. 3) Wool yarn used in flooring applications is often not recyclable. This is because there is a limit to how much filament yarn can be recovered from flooring materials, and the fibers are cut and the length of the fibers is reduced. The length will be very short, resulting in a high risk of lint formation. Wool is also significantly more expensive than synthetic alternatives and is vulnerable to pests such as moths. It is also well known. In order to overcome the shortcomings of wool yarn used for flooring, polyester and polypropylene Bulk multifilament (BCF) yarn made from pyrene and nylon is less likely to produce lint. These filament yarns are popular due to their low price and low price. By processing it with friction discs or stuffer boxes, it can be given artificial bulkiness. It can also be recycled through mechanical or chemical recycling processes. do. However, the manufacturing process of BCF yarn makes it fuzz-free and comfortable to touch. Therefore, it cannot replace the feel and texture of products made from wool yarn. Therefore, loop packs made from textured multifilaments such as BCF were Ile flooring has a natural, wool-like appearance, similar to products made from wool yarn. We were not able to achieve this feeling. Therefore, we have created a product that reproduces the appearance, feel, and texture of wool yarn. Not only can it be used as a replacement, but it is also an artificial fiber that has low fuzz and is highly recyclable. There is a demand for yarn made from Summary of the Invention
[0003] Summary of the Invention The present invention discloses a method for producing wool-like yarn from polymer multifilaments. The yarn comprises the following steps: providing a multifilament of polymer in a semi-oriented yarn; The process involves drawing and air-texturing the fibers to form yarns, which are then processed into filament yarns. The first group of fibers (also called filaments or simply fibers) forms the core of the yarn, and the The second group of fibers overfeeds against the first group of fibers to form a hair-like sheath (cover - forming step. Twist and / or cable a plurality of yarns together to form a wool-like yarn having a weight exceeding 2000 dtex (decitex). The yarn produced by this process overcomes the drawbacks of wool yarn, such as hairiness, recyclability, UV resistance, antistatic property, and abrasion resistance, while achieving an appearance, feel, and wool texture that is surprisingly similar to wool yarn. By air-processing appropriate polymer fibers, it has been shown that a useful degree of wooliness can be obtained in the yarn emerging from the air-processing process. In the present invention, this yarn is referred to as yarn and is distinguished from high dtex (tex) yarns. However, it will be understood that this yarn is also a lightweight yarn. As conventionally done in air-processing, fibers overfed by an air jet or the like are intertwined with each other to form a wool-like or hairy envelope or sheath around the core. Among the core fibers, those that are not overfed are kept relatively straight and do not intertwine in this way, or if they do, the degree of intertwining is small. In this process, the fibers may be in the state of semi-drawn yarns. This is to remove lumps or the like between adjacent fibers or to straighten them before the air-processing step . The fibers may be fully drawn or remain as semi-drawn yarns in the final product. In a preferred embodiment, the fibers are drawn at least 5% or at least 10% or at least 20 % but less than 100%. It is also possible to use semi-drawn yarns since it is possible to stretch a certain amount sufficient to untangle lumps during the air-processing stage . Please understand that when fully stretching, it may be stretched by 300% or more . The twisting process is done later. This process is done at a different time and place from the air cutting. Typically, this is done when the thread is on a reel or bobbin. The reels are then gathered together for twisting. It is possible to use yarns or different yarns, for example yarns of different colors. In the following, the term twist is intended to include cabling. In particular, the first twisting step involves twisting a number of threads together into a single strand. They can be assembled together, for example by light twisting, to form plies. The twisting can be done by alternating clockwise and counterclockwise twisting, air twisting or false twisting. Then, multiple plies are twisted together or cabled to form a wool-like material. By first bundling many threads together, it becomes easier to unwind them at high speeds. , making cabling work proceed more quickly. The fibers may be of any suitable weight depending on the desired look and feel of the final product. They may all be of the same weight, or some may be heavier than others. Some machines place heavier fibers in a sheath. Some air processing machines use a combination There may be a limit to the number of reels that can be used, so the weight of each fiber may vary. By adjusting the thickness of the core and the sheath, the relative weights of the core and the sheath can be varied. Multifilaments are available in a range of filaments from 0.5 dtex per fiber to 10 dtex per fiber. Preferably, these values are in the range of 4 to 6 dtex per fiber. This is because there is less risk of fiber breakage and it provides a more stable process. .
[0004] Moreover, the semi-oriented yarn can be provided from any suitable source. The fibers may be produced in situ at the same location or at another location. The semi-drawn yarns can be produced by any conventional process, such as by drawing or stretching. Multifilament to Bulk Multifilament (BCF) In this case, the fibers are already processed and completely The use of BCF offers certain advantages over virgin fibres. First, the initial processing adds bulk, so the BCF is heavier and more demanding for wool-like yarns. This means that the number of processing opportunities varies depending on the number of reels input. This is important when the yarn is limited by the number of strands. Also, fewer yarns are assembled and twisted. It is necessary to improve the air processing process so that it can operate more efficiently. In addition, by using textured BCF for the core fiber of the fiber, the sheath fiber This improves fiber engagement and grip.
[0005] The fibers can also have any suitable cross-section. In some embodiments, the fibers are partially oriented. The resulting multifilament has a multilobal cross-sectional shape. This is because the fibers with non-circular cross-sections are cut to create a smooth cross-section. It has a less lustrous appearance than a fibre with a matte surface, making it more similar to wool. In another embodiment, the cross section is octagonal. Semi-oriented multifilament yarn is made by combining multiple multifilament tows (fibers used in producing hemp). Each tow is placed on its own reel or bobbin and then extruded. Such tows are generally known in the art as semi-stretched tows. Partially oriented yarn (POY) is simply a loosely bound fiber. To distinguish the yarns from the heavy wool-like yarns, we refer to them as tows. It is preferable that the fibers in the tow have a lump for fastening. You should be familiar with this process, which allows the fibers to be held together. Each tow can have 10-500 filaments or 100-20 0 filaments. Furthermore, each tow is preferably 100 dtex to 1500 dtex, The preferred range of dtex is about 500 dtex to 700 dtex. The weight of each tow is multifilament. It depends on the manufacturing machine that supplies the lament, as well as the nature of the air processing machine used. The intention is to produce yarns with relatively high dtex values, and high dtex or by combining more tows in the air-processing process. I think you can see that this can be achieved by combining In cases where the number of tows is limited, it is advantageous to use a high dtex tow. In one embodiment, the air converting process is used in combination with multiple such tows. This allows the first tow to form the core of the yarn and one or more additional tows to form the overfill. The yarns may all be the same or the yarns forming the core may be different. The threads may be different from the drawn threads that form the sheath. As mentioned above, for example, only two tows may be used. When the tows forming the sheath can be combined with the tows forming the core, The dtex of the tow may be higher than that of the tow. In some embodiments, the stretching and air texturing are performed simultaneously in a continuous process. " means that the tow is not wound onto a bobbin, but rather in an in-line process prior to air processing. Stretching means that the fibers in the tow are stretched, which specifically frees them up for subsequent air processing. This is useful as a way to prevent the air from being pulled out of the process. This allows the fibers to be freed from any nips or connections that may have formed between them. The fibers may be drawn to a fully oriented state. Alternatively, only a portion of the fibers may be stretched and The fibers forming the abrasion are not stretched any further and may remain nipped. In another embodiment, all of the fibers are drawn at a draw ratio of 1.3 or greater, preferably 1.5 or greater. The fibers of the sheath may be drawn at a higher draw ratio than the core. The fibers are pulled out at a greater rate than the core fibers as they are overfed. This results in both groups of fibers being fed at equal rates. The stretching and air-texturing steps can be carried out in a conventional manner using conventional machinery. In the case of polyester, the stretching is preferably carried out at a temperature of about 180° C. The temperature may correspond to the typical temperature used during filament production to orient the polymer. The filaments or tows are then processed before or after the air processing step. It can be cooled in the process. During the air processing step, the amount of overfeeding can be determined depending on the desired results. As can be understood, the degree of overfeeding affects the volume of the sheath, and In one embodiment, the second group of filaments is preferably a 100% spunbonded yarn. The loop should be 30% to 150%, with an overfeed of about 80% being preferred.
[0006] The yarn properties are also affected by the ratio of the number of filaments in the core to the number of filaments in the sheath. In this embodiment, the ratio is between 1:1 and 1:6, and preferably about 1:2. If the sheath filaments are different, the ratio of dtex of the tire core to the dtex of the sheath should be between 1:1 and Note that it may be between 1:6 and preferably between 1:2. The yarns are available in sizes ranging from 500d to 500d depending on the weight of the filaments and the number of filaments combined to form each yarn. The dtex ranges from 0.5 to 5,000 dtex. Yarns at the lower end of this range are generally used for flooring applications. As mentioned above, heavy weight yarns are made by assembling many yarns. Two to twenty threads can be twisted or cabled together to create a wool-like texture. The resulting yarn can have a weight of over 2000 dtex, but is more commonly around 50 00 dtex or more, alternatively 10,000 dtex or more, alternatively 50,000 dtex or more. The thickness is between 2000dtex and 3000dtex. The yarns may be lightly or hard twisted, typically ranging from 30 to 400 twists per meter (TPM). As mentioned above, the yarn can be assembled in a multi-step process. In the first step, the yarn Groups are twisted together as plies. Then two or more plies are twisted together. , or cabled. This step preferably involves heat setting the yarn at a temperature in the range of 85°C to 200°C. Especially in the case of yarns twisted at 100 TPM or more or 200 TPM or more, the subsequent yarns and the subsequent This is preferred for better maintenance of twist during processing and use of the manufactured floor covering. The setting is preferably performed at a temperature lower than the stretching temperature, and is desirably performed in the temperature range of 85°C to 110°C. It is. The polymeric material used to manufacture the multifilaments is suitable for use as floor coverings. The polymer may be any suitable polymer having the necessary properties to achieve the desired results. Typically, polyester is The polymer may be selected from the group consisting of ethers, polyanides, polypropylenes, and polymers thereof. The light is particularly useful for polyesters, including PET and PBT. The present invention further relates to a tire cord (tire yarn) in wool form for the manufacture of floor coverings. The yarn is made of multifilaments of polymeric material interwoven together. forming a yarn, a first straight filament forming the core of the yarn and a second textured filament The fibers form a hairy sheath around the core, and multiple threads are twisted and / or cabled. It is used to form heavy weight yarns exceeding 2000 dtex. The yarns and filaments thereof are as described above and below. In particular, the yarn may be a blended yarn in which polymer filaments are combined with other fibers or filaments. However, yarns are essentially made up of multifilaments of a single polymer. In this sense, "consisting essentially of" means that the material is made up of at least one yarn. This means that the fibers are 99%, or at least 95%, of a single polymer. Antistatic conductive filaments, decorative filaments, reflective filaments, etc. It may also be other fibers or filament yarns that have a functional purpose. In addition, the polymer in the yarn, such as wool, may be one or more of the additional materials mixed into the polymer. The masterbatch may include a masterbatch of the antimicrobial, antifungal, antipurifying, External radiation, FR properties, stain resistance, antioxidants and pigments, or tire-related technology experts Any of the conventional masterbatches that would be intended to be added to filament yarns such as In addition, the yarn may be selected from the group consisting of a dispersion for polyester. It can be subjected to any conventional dyeing process, such as the use of dyes or acid dyes for nylon. In addition, we use space dyeing to create a variety of colors, such as hank dyeing and bobbin dyeing. You may do so. The present invention also relates to a floor covering made of the wool-like yarn described above or below. In a preferred embodiment, the floor covering is a carpet or a rug. It may be formed into standing pile such as pile, loop pile, shaggy pile, etc. The wool-like yarn can be tufted, knitted, knotted, and / or woven into floor coverings. It may also form the backing for a floor covering, and the backing may be formed from another material. [Brief description of the drawings]
[0007] The features and advantages of the present disclosure may be more readily appreciated by reference to the following drawings, in which: I understand. [Figure 1A] 1 shows a schematic diagram of the four steps of the method according to the invention. [Figure 1B] 1 shows a schematic diagram of the four steps of the method according to the invention. [Figure 1C] 1 shows a schematic diagram of the four steps of the method according to the invention. [Figure 1D] 1 shows a schematic diagram of the four steps of the method according to the invention. [Diagram 2]2 shows a cross section through a yarn produced according to the method of FIG. 1. [Diagram 3] 2 illustrates a loop pile tufted carpet incorporating yarn made according to the method of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] In the following description, embodiments and methods of implementing the present disclosure are described. Although certain aspects have been disclosed, those skilled in the art may be able to contemplate other embodiments for implementing or practicing the present disclosure. It will be easily understood that this is also possible. FIG. 1 illustrates steps in a method for making wool-like yarn according to an exemplary embodiment of the present invention. That is why. In a first step, a plurality of polyester multifilaments 1 are extruded according to FIG. IA. The yarn is then extruded from the machine 10 and rolled on rollers 2 in other conventional processes for producing semi-oriented yarn (POY). The filaments are stretched at a draw ratio of 1.05 so that they have a weight of 6 dtex per filament. A total of 96 long fibers 1 are wound onto a reel 3 as a tow 2. Before being taken up, the tow 2 is struck by an entanglement jet 30 to slightly entangle the individual filaments 1. The tows 2 are nipped together by pressing the tows together.
[0009] In the second step shown in FIG. 1B, a tow 2 of continuous polyester filaments 1 is wound on three The reels 3 are joined and textured in an air processing machine 40. The air processing machine 40 This is a standard machine available from SM. The tow 2 is first sent to the air processing station 44. Before being drawn through drawing station 42 at a draw ratio of 1.7 and a temperature of 180° C. In the air processing station 44, two of the tows 2 are cut by 80 degrees relative to the third tow 2. % overfed, air-processed jet 46 is sprayed on tow 2, overfed tow 2 However, it undulates and forms a loop around the third tow 2, which remains relatively straight. The overfed tow 2 then forms a hair-like layer around the third tow 2 forming the core 12. The tow 2 is joined at the outlet of the air processing machine 40 to form a sheath 4. The tow 2 is joined at the outlet of the air processing machine 40 to form a yarn 5 of 1480 dtex. and wound onto bobbin 6. In the third step shown in FIG. 1C, four bobbins 6 carrying air-texturized yarn 5 are lightly wound together. The ply is then combined to form ply 7. The ply has a thickness of 6000 dtex and is wound on spool 8 with a twist of 80 tprn. It is wrapped in. In the fourth step shown in FIG. 1D, two plies 7 are twisted together to form a wool yarn having a thickness of 12,000 dtex. The plies 7 are twisted at 100 tpm to form a looped yarn 9. FIG. 2 shows a cross section through the yarn 9 of FIG. 1D, showing two plies 7. Each tire ply 7 The spool is formed of four threads 5. Each thread 5 has a core 12 made of a long fiber 1 and a periphery 4 shows sheath 4. FIG. 3 shows a loop pile tufted carpet 20. The carpet 20 has a woven backing 22. The yarn 9 is made of upright loops and has tufted yarn 9 as shown in FIG. It forms Group 24. Example 1 As shown in Figs. 1A to 1D, the above-mentioned yarn 9 is used for the tying of a tufted loop pile carpet as shown in Fig. 3. This carpet is made of 14 inch gauge (6mm) with 28 needles per 10cm and is tough. The pile height is 10 mm. The finished carpet is made of weave with a smooth surface. It was similar to wool and had the appearance and feel of wool. The carpet was then subjected to a hexapod test. After 4,000 cycles, the carpet's hexapod The rating was 4.5, but after 8,000 cycles it dropped to 4, and after 12,000 cycles it remained at 4. It was. The present invention has been described with reference to specific embodiments above. These embodiments are within the skill of the art. Various modifications and alternative forms known in the art can be readily envisaged, particularly depending on the intended use. It is possible to employ different initial long fiber weights depending on the composition, without departing from the spirit and scope of the present invention. Many other modifications in addition to those mentioned above may be made to the structures and techniques described herein without the need for any special modifications. Many modifications may be made. Although specific embodiments have been described herein, these are provided by way of example only. It is merely intended to be in no way limiting of the scope of the present invention.
Claims
1. A method for producing wool-like yarns (9) from continuous filaments (1) of polymeric material for use as a raised pile in floor coverings (20), comprising the steps of: providing at least partially oriented continuous filaments of said polymeric material; drawing and air-texturing the continuous filaments to form a yarn (5), wherein a first set of straight filaments forms a core portion (12) of the yarn, and a second set of filaments is overfed over the first set of filaments to form a hairy sheath (4); and twisting and / or cabling a plurality of yarns to form said wool-like yarn (9) having a weight of more than 2000 dtex (decitex); A method comprising:
2. the plurality of continuous filaments have a dtex per filament in the range of 0.5 to 10, preferably 4 to 6, and / or are supplied by melt spinning and drawing, and / or have a multilobal cross-sectional shape; The method of claim 1.
3. providing said partially oriented continuous filaments as a plurality of multifilament tows (2), wherein each tow preferably has a dtex value in the range of 100 dtex to 1500 dtex, preferably comprising a nip for holding each tow together; a first tow forming a core portion of the yarn and at least one other tow overfeeding the first tow to form a hairy sheath; The method according to claim 1 or 2.
4. said stretching and said air texturing being carried out simultaneously in a continuous process; The method according to claim 1 or 2.
5. The stretching is carried out at a temperature in the range of 130°C to 200°C. The method according to claim 1 or 2.
6. overfeeding the second group of filaments relative to the first group of filaments by between 30% and 150%, preferably about 80%; The method according to claim 1 or 2.
7. the dtex weight ratio of the filaments in the core to the filaments in the sheath is 1:1 to 1:6, preferably 1:2; The method according to claim 1 or 2.
8. the yarn has a dtex value in the range of 500 dtex to 5000 dtex, preferably in the range of 2000 dtex to 3000 dtex, The method according to claim 1 or 2.
9. 2 to 20 threads are twisted and / or cabled to form said wool-like yarn; and / or The twisted and / or cabled yarn is twisted in the range of 30 to 400 TPM (twists per meter); The method according to claim 1 or 2.
10. further comprising heat treating the twisted and / or cabled yarn at a temperature below the drawing temperature, preferably in the temperature range of 85°C to 110°C, to retain the twist. The method according to claim 1 or 2.
11. said polymeric material is selected from the group consisting of polyester, polyamide, polypropylene and copolymers thereof, preferably polyester; and / or The yarn comprises at least 95%, preferably at least 99%, of filaments made of a single polymer; The method according to claim 1 or 2.
12. A wool-like yarn (9) for use as a raised pile in the manufacture of floor coverings (20), comprising: The yarn comprises continuous filaments (1) of polymeric material that are combined together to form a thread (5), the thread (5) having a first filament that forms a core (12) of the thread and a textured second filament that forms a hairy sheath (4) around the core; A plurality of said yarns are twisted and / or cabled to form a heavy weight yarn having a weight of greater than 2000 dtex. Wool-like yarn.
13. the polymeric material comprises one or more masterbatches selected from the group consisting of antimicrobial, antifungal, UV resistant, flame retardant, stain resistant, antioxidant, and pigment; 13. The wool-like yarn of claim 12.
14. 14. A fabric comprising a wool-like yarn according to claim 12 or 13, the wool-like yarn being tufted, knitted, knotted and / or woven to form a raised pile (24). Floor covering (20).