High-bulk yarn and method for producing the same

Abstract

The method of manufacturing a high bulk continuous multifilament yarn involves a number of separate steps. In the first step, a plurality of filaments of a polymer are melt spun to form a partially oriented yarn (POY). In a second step, the POYs are drawn and textured to form a drawn yarn, and the texturing is carried out in a friction texturing process. Subsequently, at least two plies of the drawn textured yarn are twisted and / or cabled and subsequently heat set to obtain a high bulk continuous multifilament yarn.

Description

Technical Field

[0001] The present invention relates to fibers. More specifically, it relates to a method for manufacturing high-bulk yarn (thread) and a floor covering made from such yarn.

Background Art

[0002] Bulk continuous filament (BCF) yarn has many applications in daily life. One of them is carpet. However, to meet the demands of the carpet industry, strength and elasticity are required and the feel, appearance, and coverage rate of the product must also be within an acceptable range. To meet these specifications, it is necessary to manufacture high-density carpets with a high grams per square meter (GSM), which results in increased material consumption and higher costs for the final product. . Reducing the GSM is out of the question as it directly affects the quality of the product. Another option is to increase the bulk of the BCF yarn through texturing. However, BCF yarn is usually almost completely stretched or fully stretched when passed over a heated godet after the extrusion process. Yarn in this state is called high-oriented yarn (HOY) or fully drawn yarn (FDY). Texturing by friction is not effective as it depends on the elongation of the yarn. Instead, BCF yarn is traditionally textured using a stuffer box texturing process. In the stuffer box texturing process, the yarn after the extrusion and stretching process is placed in a stuffer box machine and compressed axially. The stuffer box usually has two friction feed rolls for pushing the yarn into the cavity and a constrained gate that crimps the yarn while applying back pressure. This is a single-step process, and the extrusion process and the in-line are substantially the same. They are carried out at the same speed. However, the resulting textured yarn lacks sufficient bulkiness and also lacks uniformity, failing to meet the requirements of the carpet industry. Therefore, the covering property of carpets made from such yarns remains low. To compensate for the poor covering property, the stitch rate, gauge, pile height, and yarn denier can be increased, but they are not optimal. Examples of such BCF yarns are described in EP 0547176 B1. Therefore, it is necessary to provide a yarn that can use materials more efficiently while maintaining the feel, appearance, and overall quality of the product to improve the covering property.

[0003] In a first embodiment of the present invention, a method for manufacturing a high-bulk (high-loft) continuous multifilament yarn as described in claim 1 is provided. The method is as follows. First, a plurality of filaments of the polymer are melt-spun to form a partially oriented yarn (POY). Next, one or more partially oriented yarns are drawn and textured to form a drawn-textured yarn. At this time, the texturing is carried out in a friction texturing process. Finally, at least two plies of the drawn-textured yarn are twisted together or cabled, and the twisted plies are heat-set to form a high-loft continuous multifilament yarn. The continuous multifilament yarn thus formed has much improved bulkiness compared to BCF yarn. Therefore, when used for carpets and floor coverings, for the same denier, a higher coverage rate can be obtained. can be obtained. Throughout this disclosure, terms related to "steps" such as "first" refer to a multi-step process in which the next step (such as the second step) is executed after the completion of the previous step (such as the first step), and different steps are sequentially executed by different machines in an orderly manner. Such steps include a plurality of (sub) processes, and each process ends by winding the yarn onto a bobbin, hank, etc., and / or moving the yarn from one machine to another machine. Thus, in a multi-step process, each step is independent of other steps in terms of speed, whether measured linearly or in terms of mass. Furthermore, even if a failure, stop, or error occurs in one process, it is not necessary to interrupt other processes. In this embodiment, the first step may be performed at a speed higher than that of the second step, preferably at least twice, three times, five times, or up to ten times the speed This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. As described above, the first step consists of melt-spinning a plurality of filaments using a spinneret to form partially oriented yarn (POY). POY is a yarn composed of filaments that are only partially drawn and crystallized. The polymer includes at least one of polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). The weight of each filament may be 2 denier per filament (dpf) or more, 3 dpf or more, 7 dpf or more, or 12 dpf or more, 15 dpf or more, and even 20 dpf or more. Even if a failure, stop, or error occurs in one process, it is not necessary to interrupt other processes. In this embodiment, the first step may be performed at a speed higher than that of the second step, preferably at least twice, three times, five times, or up to ten times the speed This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. As described above, the first step consists of melt-spinning a plurality of filaments using a spinneret to form partially oriented yarn (POY). POY is a yarn composed of filaments that are only partially drawn and crystallized. The polymer includes at least one of polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). The weight of each filament may be 2 denier per filament (dpf) or more, 3 dpf or more, 7 dpf or more, or 12 dpf or more, 15 dpf or more, and even 20 dpf or more. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. This speed is measured at the completion of the step. The first step can also be completed by winding the POY onto one or more reels or bobbins. Yes. Among these, 10 dpf is considered optimal. Although the upper limit has not been specified, it will generally be less than 50 d pf. It is common for the filaments to be used in the range of 0.5 dpf to 3 dpf. However, the high weights currently proposed are extremely important for implementing the present invention, as will be described later. After extrusion, the filaments are cooled in a quench chamber. Since the extruded filaments have a relatively large thickness compared to conventional POY, it may be necessary to significantly increase the length of the quench from a short quench of about 1 m in the past. The effective quench length can be 1.2 m or more, preferably 1.5 m or more or 1.8 m or more. The air flow rate in the quench chamber can be increased to at least 0.9 m / s in order to further improve the efficiency of the filament cooling process. In this specification, the distance between the spinneret and the spinning finish applicator is regarded as the length required for rapid cooling. Since the filaments with high dpf have a large weight and a relatively small surface area, it is necessary to increase the length of cooling to complete the cooling process. The cooled POY is wound onto a bobbin and the first step is completed. The POY process may include additional processes such as lightly winding the filaments and using an air nip to maintain the bundle of yarns for winding and unwinding. The POY created in the first step can have a weight of 100 denier to 1000 denier, preferably 200 denier to 4 00 denier, or about 240 denier. Considering the relatively heavy weight of the filaments, it can be composed of 10 to 500 filaments, or about 25 filaments. ​​​​​​​​​​​​The second step is to simultaneously draw-texture at least one POY obtained in the first step by false twist texturing or friction disk texturing to produce a drawn textured yarn. The second step may also start by rewinding the POY from one or more bobbins. To impart bulkiness to the POY, drawing and texturing processes are common. According to the present invention this is done in a friction texturing process also known as false twist texturing or friction disk texturing. In the friction texturing process, the yarn is first heated and then passed through a plurality of partially overlapping disks that rotate about an axis generally parallel to the axis of the yarn as the yarn is drawn out. The disks impart twist to the yarn. Depending on the configuration of the disks this results in an S-twist yarn or a Z-twist yarn. In conventional texturing processes, to obtain a more stable yarn, the yarn is heated to a heat-setable temperature through a second heater unit In the procedure according to the present invention, this heat-setting step after the friction texturing stage can be omitted. Omitting or reducing the temperature of this step can not only save a significant amount of energy but also avoid a reduction in the bulk of the yarn that heating can cause. In some cases, this secondary heating may be limited to 160 °C or less, 140 °C or less, 120 °C or less, 100 °C or less. In the friction texturing process, the ratio of diameter to yarn speed, i.e., the D / Y ratio, is an important parameter that determines the degree of twist imparted to the textured yarn. This represents the ratio of the lateral speed to the yarn speed at the outer circumference of the friction disk that engages the yarn. The actual speed at which the friction texturing is carried out is considerably higher than the speed of the step of melt-spinning the filaments higher than the speed of the step of melt-spinning the filaments ​​​​​It should be noted that it is low. Therefore, it is difficult to perform friction spinning and melt spinning at the same time Therefore, the produced POY is wound on a bobbin and subjected to friction texture processing in the next process. In the general manufacturing process of BCF yarn, the texture processing of the stuffer box is performed in the same process as melt spinning and drawing, so these processes are very different from those performed at the same speed Furthermore, the friction texture processed yarn becomes a helical three-dimensional crimp This can provide a more uniform bulk over the entire area of the material, so please understand that it is desirable for floor coating applications. The yarn textured using the stuffer box texturing essentially results in a very non-uniform crimp The friction texturing step can be carried out between 500 m / min and 1000 m / min, preferably 700 m / min or less. It will be understood that by reducing the linear velocity, the D / Y ratio can be increased In contrast, the typical speed at which POY is produced in the first step far exceeds 1 000 m / min, or exceeds 2000 m / min and may reach 3500 m / min. The second step should be carried out under appropriate conditions such as temperature and D / Y ratio. The temperature of drawing and texturing is in the range of 130°C or higher and 230°C or lower, or 160°C or higher and 230°C or lower, preferably 170°C or higher and 200°C or lower , more preferably in the range of 170°C or higher and 190°C or lower, or 180°C or higher and 200°C or lower. The D / Y ratio will be in the range between 1.5 and 2.5, preferably between 1.7 and 2.3, more preferably between 1.85 and 2 . Conventional POY consists of low dpf filaments and cannot withstand such a high lateral speed of the friction disk As a result, it can withstand the high false twist in the texturing process It is considered impossible. This leads to an unacceptable level of damage. Therefore, in the second step, it should be noted that the final weight of the yarn is reduced to about 60% of the weight of the POY. Therefore, the initial POY filaments of 3 dpf are reduced to 2 dpf, and the POY filaments of 10 dpf are reduced to about 6 dpf. According to the present invention, the heavier POY obtained in the first step can be subjected to a higher degree of texture processing. The end of the second step is completed by rewinding the drawn textured yarn onto a bobbin or hank, preferably without first heat setting. To make a single-density drawn textured yarn, only one POY can be textured and wound onto a bobbin or hank. However, two, three, or more POYs can also be drawn textured simultaneously to make double-density, triple-density, or multi-density drawn textured yarns. Twisting two POYs in opposite directions (S twist and Z twist) for double-density texture processing is preferred because it results in a drawn textured yarn without residual torque. Furthermore, the multi-density drawn textured yarn has more bulk compared to the single-density drawn textured yarn. The thickness of the drawn textured yarn is in the range of 200 to 600 denier, preferably around 300 denier. As such, at least two drawn textured yarns may be interlaced to form one ply. It is ideal to interlace four drawn textured yarns. The yarns may be nipped or lightly twisted to improve the overall stability of the ply, but this is done optionally. The purpose of the interlacing is for the ply intended for later processes. For the purpose of interlacing, it is intended for the ply in later processes. is to achieve a weight that is sufficiently high. The weight of the entangled draw-texture ply is in the range of 400 to 2400 denier, preferably 500 denier or more, for example in the range of 1000 to 1500 denier and can be. Entanglement can be carried out, for example, without first winding onto a bobbin, by combining a plurality of yarns emerging from the draw-texturing process, without a separate process . However, it is preferable to provide a step of winding from a bobbin to a bobbin, for example, separately from the draw-texturing process. After the second step and the optional entanglement step, proceed to the third step, where at least two plies of the draw-textured yarn are twisted and / or cabled. Each of the plies may be greater than 500 denier. Twisting and / or cabling is carried out in the range of 30 to 400 turns per meter (TPM), preferably 110 to 250 TPM, more preferably 110 to 210 TPM, or 110 to 200 TPM. During twisting, a permanent and characteristic texture may be imparted to the yarn. Twisting together a number of plies is understood to be advantageous in terms of creating additional bulk in the yarn. For example, by passing a heated medium such as air, steam, liquid, etc. This step is such that when the yarn passes through the heat-setting device, heat is transferred from the medium to the twisted yarn. The temperature of the medium is chosen so that the yarn does not melt. Also, when the temperature of the medium is above the melting point of the yarn, the exposure time, i.e., the residence time, is shortened to prevent the yarn from melting. Heat setting is in the range between 85 °C and 220 °C, preferably between 110 °C and 190 °C, more preferably between 160 °C and 180 °C. For example, passing a heated medium such as air, steam, liquid, etc. through it. In this step , when the yarn passes through the heat-setting device, heat is transferred from the medium to the twisted yarn. The temperature of the medium is chosen so that the yarn does not melt. Also, when the temperature of the medium is above the melting point of the yarn, the exposure time, i.e., the residence time, is shortened to prevent the yarn from melting. Heat setting is in the range between 85 °C and 220 °C, preferably between 110 °C and 190 °C, more preferably between 160 °C and 180 °C. and between 220 °C, preferably between 110 °C and 190 °C, more preferably between 160 °C and 180 °C. It is carried out at a temperature. The heat set stabilizes the twist of the yarn and eliminates unwanted torquing. It will be understood. The heat set does not impair the elasticity and overall appearance of the yarn. None. The heat set is not excluded from being carried out in the same step as twisting and / or cabling. However, it is preferred that the heat set be carried out in a separate step. The heat set may be carried out much faster than twisting and / or cabling. It may be desirable to first wind the twisted yarn onto a reel or bobbin, and then carry out the heat set in a subsequent step. Therefore, a large number of bobbins are supplied into the creel and fed to a heat setting device such as a device using saturated steam or superheated steam. The heat set is preferably carried out with the yarn in a relaxed state. In such a continuous process, the heat set temperature is between 110 °C and 220 °C. A discontinuous heat setting process such as an autoclave is also possible, but this is also preferably carried out in a relaxed state, i.e., not in a tightly wound state like a bobbin but in a hank state. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. It will be understood. The heat set does not impair the elasticity and overall appearance of the yarn. None. The heat set may be carried out much faster than twisting and / or cabling. It may be desirable to first wind the twisted yarn onto a reel or bobbin, and then carry out the heat set in a subsequent step. Therefore, a large number of bobbins are supplied into the creel and fed to a heat setting device such as a device using saturated steam or superheated steam. The heat set is preferably carried out with the yarn in a relaxed state. In such a continuous process, the heat set temperature is between 110 °C and 220 °C. A discontinuous heat setting process such as an autoclave is also possible, but this is also preferably carried out in a relaxed state, i.e., not in a tightly wound state like a bobbin but in a hank state. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. For this purpose, a large number of bobbins are supplied into the creel and fed to a heat setting device such as a device using saturated steam or superheated steam. The heat set is preferably carried out with the yarn in a relaxed state. In such a continuous process, the heat set temperature is between 110 °C and 220 °C. A discontinuous heat setting process such as an autoclave is also possible, but this is also preferably carried out in a relaxed state, i.e., not in a tightly wound state like a bobbin but in a hank state. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. It will be understood. The heat set does not impair the elasticity and overall appearance of the yarn. The heat set is preferably carried out with the yarn in a relaxed state. In such a continuous process, the heat set temperature is between 110 °C and 220 °C. A discontinuous heat setting process such as an autoclave is also possible, but this is also preferably carried out in a relaxed state, i.e., not in a tightly wound state like a bobbin but in a hank state. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. None. The heat set is preferably carried out with the yarn in a relaxed state. In such a continuous process, the heat set temperature is between 110 °C and 220 °C. A discontinuous heat setting process such as an autoclave is also possible, but this is also preferably carried out in a relaxed state, i.e., not in a tightly wound state like a bobbin but in a hank state. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. None. In a discontinuous process, the heat set is carried out at a temperature of 80 °C to 130 °C. After twisting and / or cabling, for additional bulk, a freeze treatment may also be carried out. The freeze treatment may be carried out in a freeze box in a continuous process as part of the heat set process. None. None. The high-bulk continuous multifilament yarn obtained according to the above method has a bulk of at least 12 cm3 / g, preferably at least 14 cm3 / g, more preferably at least 16 cm3 / g. This is a significantly higher value than that of conventional textured BCF yarn. The total weight of the yarn is 1000 den. None. None. Exceeding Neale, generally exceeding 1500 denier, or 2000 denier. The present invention provides a yarn having a high bulkiness, as a result, reducing the consumption of raw materials for the production of the final product, and as a result, reducing the manufacturing cost. The high-bulk yarn of the present invention has an appearance, touch and covering property without affecting the properties of the final product such as, compared with the conventional bulky continuous filament yarn it may result in a material cost that is 20 - 50% lower. Furthermore, the high-bulk yarn according to the present invention has been shown to have excellent elasticity compared with the conventional bulky continuous filament yarn. The bulk is measured using a standard bulk meter such as available from Wira Instrumentation Ltd. The measurement is carried out by applying a load of 500 g to an area of 100 mm × 60 mm. In another embodiment of the present invention, a high-bulk continuous multifilament yarn is provided. This multifil ament yarn is made using the method according to the first aspect of the present invention. In another embodiment of the present invention, a high-bulk continuous multifilament yarn is provided. This high-bulk continuous multifilament yarn consists of a plurality of plies, and each ply further includes at least one drawn textured yarn. The drawn textured yarn is created using the method steps and processes described above and below. The drawn textured yarn may refer to a yarn having a helical three-dimensional crimp. Alternatively or additionally, the drawn textured yarn may include false twist, and the false twist is obtained in a friction texturing process. The drawn textured yarn further includes one or more partially oriented yarns (POY). Moreover, each of the partially oriented yarns consists of a plurality of continuous filaments of the polymer. The weight of the filaments of the POY is 2 dpf or more and 3 dpf or less before draw texturing. ​ Above, it may be 5 dpf or more, 7 dpf or more, 10 dpf or more, 12 dpf or more, and even 15 dpf or more. When POY is drawn texturized, the final weight of the drawn texturized filament is 2 dpf or more, 3 dpf or more, 4 dpf or more, 6 dpf or more, 7.5 dpf or more, or 9 dpf or more. The bulk of the high-bulk continuous multi filament yarn is at least 12 cm3 / gm, preferably at least 14 cm3 / gm, more preferably at least 16 cm3 / gm may be sufficient. In another preferred embodiment, two or more plies of the high-bulk continuous multifilament yarn are twisted together, or cabled, and then heat set. Optionally, additional fleece treatment is applied. The resulting high-bulk continuous multifilament yarn is 1000 denier or more, preferably 1500 denier or more, more preferably 2000 denier or more, for example, between 1800 denier and 4000 denier in weight. In one embodiment, the high-bulk yarn consists of single-component filaments. In other words, the filaments forming the high-bulk high yarn are formed from a single component or material. The high-bulk single-component yarn may also be advantageous in terms of providing a final product that is easy to recycle. Preferred materials include, but are not limited to, polyesters such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). Of course, the high-bulk yarn may also be a multi-component yarn. In this case, the filaments may be side-by-side type filaments or core-sheath filaments of two or more different materials. The filaments can be composed of, for example, a combination of PET and PBT, or a combination of other suitable and beneficial materials. In yet another aspect, a floor covering material is provided that includes a base backing and a pile consisting of high-bulk continuous multifilament yarns. Examples of the floor covering material include, but are not limited to, carpets, rugs, mats, and the like. The high-bulk yarns can be tufted onto the base backing to form the floor covering material, or the bulky yarns can be woven, knotted, or knitted onto the base backing to form the floor material. In another embodiment, the high-bulk yarns are cut to form a cut-pile floor covering material. Alternatively, the high-bulk yarns can be used in the form of loop piles. The floor covering material according to the present invention provides a soft feel, a high-class appearance, and high elasticity while reducing the weight and raw material consumption of the final product, and thus can be said to be an improved version of similar prior art materials. BRIEF DESCRIPTION OF THE DRAWINGS The features and advantages of the present disclosure will be described with reference to the following drawings of exemplary embodiments. A diagram schematically showing steps of a method according to the present invention. A diagram schematically showing steps of a method according to the present invention.

[0004] A diagram schematically showing steps of a method according to the present invention.

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 2

Figure 3

DETAILED DESCRIPTION OF THE INVENTION

[0005] DETAILED DESCRIPTION OF THE INVENTION The following description shows embodiments of the present disclosure and methods of implementing the same. Although several aspects of the present disclosure have been disclosed, those skilled in the art will readily envision other forms that are possible for implementing the present disclosure. FIG. 1 shows the steps of a method for manufacturing high bulk yarn according to an exemplary embodiment of the present invention. The given numerical values and values are specific, one example, and it will be understood that many alternative process parameters may be applicable. In a first step, according to FIG. 1A, a plurality of continuous filaments 1 of polyester are extruded from an extruder 10. These filaments 1 are quenched in a quench chamber 24 and drawn onto a roller 20 to produce a partially oriented yarn (POY) 2. The quench chamber 24 has an effective quench length E of 1.8 m, and in order to complete the process of cooling and solidifying the filaments 1, the quench air speed in the quench chamber is set at 0.9 m / s. The effective quench length E is set between the extruder 10 and the spin finish applicator 18. The filaments 1 are spin drawn to have a weight of 10 denier (dpf) per filament. A total of 24 filaments 1 are wound onto a first bobbin 3 of 240 denier as POY 2. In a second step, shown in FIG. 1B, two first bobbins 3 wound with POY 2 of continuous polyester filaments 1 are combined and drawn textured in a double density friction texturing machine 40. Processing is performed. POY2 is conveyed to the friction disk 47 by a number of rollers such as the input roller 41 The friction disk 47 twists the POYs2 in the section between the input roller 41 and the friction disk 47. In the same section, the POY2 passes through the first heater 43 that heats the twisted POY2 to 180 °C for twisting. In the texturing process, a D / Y ratio of 1.9 is used. The central roller 45 is arranged after the first heater 43 and draws the twisted POY at a draw ratio of 1.7 to form the drawn textured yarn 4. By the drawn texturing process, the weight of each filament of the drawn textured yarn is reduced to about 60% of the weight of the POY filament 1 and becomes about 6 dpf. Next, the drawn textured yarn 4 is conveyed to the second heater 49 and the overfeed roller 51. This overfeeds the drawn textured yarn 4 to form and set the crimp. However, it has been found that the second heater may be omitted or set to a lower temperature. The obtained drawn textured yarn 4 of about 300 denier is wound onto the third bobbin 6. Figure 1C shows four third bobbins 6. This conveys the drawn textured yarn 4 that is interlaced by the interlacing jet 50 to form a single ply 5. The ply 5 has a weight of 1200 denier and is wound onto the fourth bobbin 8. Here, the blending between bobbins is performed as a separate step. This enables each to be carried out independently at an optimal speed. It is also possible to perform it at the rear end of the draw texturing step, and it will be understood that a number of drawn textured yarns 4 are interlaced before being wound onto the third bobbin 6. ​​​​​​​​​​​​​ In the third step shown in FIG. 1D, two plies 5a, b from two fourth bobbins 8a, b are twisted or cabled to form a high-bulk yarn 7 having a thickness of 2400 denier. The cover ply 5b is twisted around the core ply 5a by rotating the cover bobbin 8b around the core bobbin 8a as shown by rotation R in the figure. The core ply 5a remains untwisted. The plies 5a, b are twisted at 110 turns / m (TPM) and wound onto a fifth bobbin 9. In the next step shown in FIG. 1E, three fifth bobbins 9 having the high-loft yarn 7 are simultaneously carried to a freeze box 60 to achieve further loftiness, and the high-loft yarn 7 is carried to a heat-setting tunnel 70 where it stabilizes at a temperature of about 170°C. The three heat-set high-bulk yarns 7 are each wound onto a separate sixth bobbin 13. FIG. 2 shows a cross-section through the high-bulk yarn 7 of FIG. 1E, showing two plies 5. Each of the plies 5 is formed of four drawn-textured yarns 4, and each of the drawn-textured yarns 4 is further composed of two POYs 2 each having 24 continuous filaments 1. The cross-section is purely illustrative, and it should be understood that the individual POYs are no longer distinguishable in reality. FIG. 3 shows a cut-pile tufted carpet 100. The carpet 100 has a backing 102 of woven fabric, in which high-loft yarns 7 as shown in FIGS. 1 and 2 are tufted. The yarn 7 forms the upright pile 104. Examples of Embodiments Table 1 shows a comparison between a carpet made from the yarn according to the present invention and a conventional yarn. This table includes ​​​​​​​​​​​​The characteristics of the yarn, such as the material, weight, filament weight, and bulkiness of the yarn, are described together with the characteristics of the carpet, such as the carpet gauge , stitch rate, pile characteristics, etc. The last column is , the performance of each carpet in the Floor Covering Test (Hexapod test), and the overall evaluation of the carpet. The overall evaluation was made by an independent user group comparing the carpets based on appearance and quality. All carpets had approximately the same coverage rate of about 1050 grams per square meter (G SM) and were composed of PET filaments. Furthermore, a comparison was made between conventional car pets and the carpets according to the present invention having a lower coverage rate. The evaluation was made based on the conventional carpet as a reference, and the feel and appearance of the carpets according to the present invention relative to the conventional carpet were independently evaluated. The feel is related to the coverage rate of the carpet. When the coverage rate is low, the backing of the carpet is felt and an uncomfortable feeling is felt when walking. On the other hand, the appearance is related to the bulkiness of the carpet. The higher the bulkiness of the yarn, the more luxurious the appearance of the carpet becomes. . The hexapod indicates the rate at which pull was achieved at 4000, 8000, and 12000 cycles in the hexapod drum test. The rate of the hexapod referred to in this specification was obtained using the D 5252 - 98a (2003 ) standard regarding the operation of a hexapod tumbling drum tester with a weight of 3.8 kg. This test was carried out using a standard upright vacuum cleaner attached to the hexapod drum tester. The hexapod drum tester is equipped with a rotating drum used as an instrument for testing pile floor coverings. The carpet sample was placed inside this rotating drum together with metal balls with polyurethane studs, and physical by traffic into the drum, and physical Simulate the impact. Through this accelerated test, the ability of the carpet to withstand crushing and matting is specifically evaluated. The hexapod test measures the elasticity of the carpet. As shown in Table 1, the carpet according to the present invention is superior to carpets using conventional PET yarns in the same denier-filament range. The 12,000 hexapod evaluation of carpets made of high-bulk yarns is up to 2.5 at most, while the evaluation of conventional carpets was only 1. This result indicates that due to the high bulkiness that prevents fiber crushing, the fibers are less likely to break down even after long-term use. The bulk of the yarn is measured in units of cc / gm, which is the inverse of the density unit. For the measurement of bulk, a yarn bulk meter manufactured by WIRA with a chamber of 100 x 60 mm was used. At that time, a hank of yarn with a known weight and length is placed in the bulk meter. The chamber is closed and the hank is pressed with a uniform weight of 0.5 kg. The volume of the measured part of the hank is measured, and the bulk is calculated as the ratio of the volume to the weight per unit length. As shown in Table 1, the high-bulk yarn according to the present invention clearly shows a higher bulk value compared to conventional BCF yarns available in the same denier range. Furthermore, it can be seen that the yarn according to the present invention provides equivalent or slightly improved results even when the constructed carpet has a much lower gsm than conventional carpets. Lines 9 to 11 in Table 1 show carpets made with a relatively low coating rate of 800 gsm compared to carpets using normal PET BCF yarns having a coating rate of 1040 gsm. However, both user evaluation and hexapod evaluation show results equivalent to or better than those of the carpet according to the present invention. Therefore, according to the present invention show results equivalent to or better than those of the carpet according to the present invention. Therefore, according to the present invention The high-bulk yarn according to the present invention can be said to be superior to other products even when the covering ratio is a low value. It should be noted that this result is achieved with both fleece yarn and straight yarn. As described above, the present invention has been described with reference to specific embodiments. Those skilled in the art will easily be able to envision various changes and alternative forms that are well-known to them. In particular, different initial filament weights can be employed according to the intended use. Without departing from the spirit and scope of the present invention, many changes can be made to the structures and techniques described herein in addition to those described above. Therefore, although specific embodiments have been described, these are merely examples and do not limit the scope of the present invention. JPEG2025517055000001.jpg210100​

Claims

1. 1. A method for producing a high bulk continuous multifilament yarn for use as pile in floor coverings, comprising: In a first step, melt spinning a plurality of filaments of a polymer to form a partially oriented yarn; in a second step, drawing and texturing one or more partially oriented yarns by a friction texturing process to form a drawn false-twisted yarn; In a third step, twisting and / or cabling at least two plies of the draw-twisted yarn in the range of 30 to 400 turns / m and heat-setting the twisted plies to form the high bulk continuous multifilament yarn having a weight of at least 1111.11 dTex (equivalent to 1000 denier); A method comprising:

2. an intermediate step after the second step, In the intermediate step, at least two, and optionally four, of the drawn false-twisted yarns are entangled to form a single ply of the drawn false-twisted yarns. The method of claim 1.

3. The following requirements: a) the stretching and texturing is carried out at a temperature range of 130°C to 200°C; b) the twisting and / or cabling is performed in the range of between 110 and 250 turns per meter (TPM); c) the heat setting is carried out at a temperature in the range of 80°C to 220°C; d) said first step comprises quenching said partially oriented yarn, wherein the effective quench length is greater than 1.2 m, preferably greater than 1.5 m, and more preferably greater than 1.8 m; e) each ply of said draw-twisted yarn has a weight greater than 555.55 dTex (500 denier); f) the high bulk continuous multifilament yarn has a thickness of at least 12 cm using the test method described in the specification ３ / gm, preferably at least 14 cm ３ / gm, more preferably at least 16 cm ３ / gm bulk g) subjecting said high bulk continuous multifilament yarn to a friezing process, preferably in a fleece box; The method of claim 1 or 2, comprising one or more of:

4. the polymer comprises at least one of polyethylene terephthalate (PET) and polybutylene terephthalate (PBT); The method according to claim 1 or 2.

5. The filaments are monocomponent filaments. The method according to claim 1 or 2.

6. the friction texturing process is carried out using friction discs with a friction disc diameter to yarn speed (D / Y) ratio of greater than 1.5, preferably greater than 1.7, more preferably greater than 1.9; The method according to claim 1 or 2.

7. the filaments in the partially oriented yarn at the completion of the first step have a weight per filament of greater than 2.22 dTex, preferably greater than 3.33 dTex, preferably greater than 7.77 dTex, preferably greater than 13.33 dTex (equivalent to greater than 2 denier per filament (dpf), or greater than 3 dpf, or greater than 7 dpf, or greater than 12 dpf, respectively); The method according to claim 1 or 2.

8. The first step is carried out at a higher speed than the second step, preferably at least 2 times, preferably 3 times or more, preferably 5 times or more, and up to 10 times faster; The method according to claim 1 or 2.

9. said heat setting of said twisted plies to obtain said high bulk continuous multifilament yarn is carried out in a fourth step subsequent to twisting and / or cabling at least two plies of said draw-textured yarn, and is preferably carried out in a relaxed state; The method according to claim 1 or 2.

10. 1. A high bulk yarn for use as pile in floor coverings, comprising a plurality of plies; each of said plies further comprising at least one draw-twist yarn; the at least one drawn false-twisted yarn comprises filaments made of a polymer; the at least one drawn false-twisted yarn is false-twist friction textured to have a helical texture; the plies are twisted and / or cabled together in a range of 30-400 turns / m and heat set in the twisted / cabled state; The weight of the high bulk yarn is at least 1111.11 dTex (equivalent to 1000 denier), The bulk of the high bulk yarn (as defined by the test method described in the specification) is at least 12 cm ３ / g, optionally at least 14 cm ３ / g, or at least 16 cm ３ / g, high bulk yarn.

11. The filaments are monocomponent filaments. The high bulk yarn of claim 10.

12. The weight is preferably greater than 1666.66 dTex (corresponding to 1500 denier), more preferably greater than 2222.22 dTex (corresponding to 2000 denier), The high bulk yarn of claim 10. 。

13. the polymer comprises at least one of polyethylene terephthalate (PET) and polybutylene terephthalate (PBT); The high bulk yarn of claim 10.

14. the weight of said filaments is greater than 2.22 dTex per filament, preferably greater than 3.33 dTex, preferably greater than 4.44 dTex (corresponding to greater than 2 denier / filament, greater than 3 denier / filament, and greater than 4 denier / filament, respectively); The high bulk yarn of claim 10.

15. A flooring material, comprising: a substrate backing; and A pile made of the high bulk yarn according to any one of claims 10 to 14; Equipped with The high bulk yarns are preferably tufted, knitted, knotted, and / or woven and / or cut against the substrate backing to form a cut pile floor covering material.

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