[go: up one dir, main page]

US20020197444A1 - Method for preparing poly (trimethylene terephthalate) carpet - Google Patents

Method for preparing poly (trimethylene terephthalate) carpet Download PDF

Info

Publication number
US20020197444A1
US20020197444A1 US10/077,310 US7731002A US2002197444A1 US 20020197444 A1 US20020197444 A1 US 20020197444A1 US 7731002 A US7731002 A US 7731002A US 2002197444 A1 US2002197444 A1 US 2002197444A1
Authority
US
United States
Prior art keywords
carpet
poly
yarns
trimethylene terephthalate
heat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/077,310
Other languages
English (en)
Inventor
Kyool Lee
Young Choi
Jong Lee
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hyosung Corp
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to HYOSUNG CORPORATION reassignment HYOSUNG CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHOI, YOUNG CHAN, LEE, JONG BOK, LEE, KYOOL SEOP
Publication of US20020197444A1 publication Critical patent/US20020197444A1/en
Priority to US10/777,319 priority Critical patent/US20040161582A1/en
Priority to US11/082,581 priority patent/US20050160570A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/04—Treatments by energy or chemical effects using steam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/08—Properties of the materials having optical properties
    • D06N2209/0807—Coloured
    • D06N2209/0823—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/08—Properties of the materials having optical properties
    • D06N2209/0807—Coloured
    • D06N2209/083—Multi-coloured
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/147—Stainproof, stain repellent
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1685—Wear resistance
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Definitions

  • the present invention relates, in general, to a method for preparing a poly(trimethylene terephthalate) (PTT) carpet, and in particular, to a method for preparing a poly(trimethylene terephthalate) carpet whose quality, functionality, and workability are improved by optimizing processing conditions of the post-processes comprising cabling, heat setting, tufting, dyeing, becking, and shearing.
  • nylon carpets which are resistant to staining by common food dyes are currently in high demand.
  • nylon carpets In order to be stain-resistant, nylon carpets must either be treated with a stain-resist chemical or the nylon fibers must have a stain-resist agent incorporated within the polymer.
  • U.S. Pat. No. 5,662,980 discloses carpets made from poly(trimethylene terephthalate) bulked continuous filament modified cross-section yarn, in which poly(trimethylene terephthalate) bulked continuous filament modified cross-section yarns used to produce a carpet have excellent stain-resistance, as well as good bending recovery and pile height retention.
  • the carpet made from poly(trimethylene terephthalate) BCF modified cross-section yarns has good texture retention.
  • the above invention has disadvantages in that, because spin finishes are coated after a supplying roller, a large friction is exerted on the threads passing through the supplying roller, resulting in many yarn cuttings and thus poor workability.
  • Another disadvantage results from the yarn condensing which should be conducted at high temperatures by a condensing device with concurrent operation of a bulking device.
  • yarns are so poorly condensed that the piles are excessively frayed during the post-processes, and the carpet is poor in appearance.
  • the present invention provides a method for preparing a poly(trimethylene terephthalate) carpet, comprising the steps of:
  • FIG. 1 illustrates an modification ratio and a arm angle of a poly(trimethylene terephthalate) carpet modified cross-section yarn according to the present invention
  • FIG. 2 schematically illustrates a production of a poly(trimethylene terephthalate) carpet modified cross-section yarn according to the present invention
  • FIG. 3 is a flow chart schematically illustrating a production of a poly(trimethylene terephthalate) carpet according to the present invention.
  • a carpet of the present invention is produced from poly(trimethylene terephthalate) yarns.
  • the carpet has excellent resiliency, stain-resistance, and dyeing property to disperse dye, and also has excellent elastic recovery and pile height retention in comparison with a poly(ethylene terephthalate) carpet or a poly(butylene terephthalate) carpet.
  • the poly(trimethylene terephthalate) carpet according to the present invention is useful as a high quality carpet for use in home or office.
  • the carpet of the present invention can be applied to produce a cut pile style carpet, a loop pile style carpet, a combination style carpet, a mat, and a carpet.
  • poly(trimethylene terephthalate) modified cross-section yarns used to prepare the carpet of the present invention are produced as follows:
  • PTT polymer with an intrinsic viscosity of 0.8 to 1.2 and a moisture content of 50 ppm or less is melt-spun at 245 to 265° C. through a spinning nozzle 1 .
  • the nozzle has a Y-shaped cross-section, 40 holes or more, a modification ratio of 1.5 to 3.5, and an arm angle of 5 to 40°.
  • PTT yarns have excellent bulk property, spinning efficiency, and tufting efficiency.
  • ‘arm angle’ means an acute angle formed by two lines extended from both edges of one arm of a filament in grey yarns with a Y-shaped cross section.
  • spun filaments 2 moving at a speed of 0.4 to 0.6 m/min are cooled at 10 to 25° C. in a cooling zone 3 , and subjected to a spin finish step, in which cooled yarns are oiled with the use of a knit type oiling agent or a water soluble oiling agent through two phases in a finish applicator 4 , so that lubrication property, and smoothness of yarns are increased and yarns are highly condensed.
  • the resulting yarns are passed through a nozzle 5 for inhaling yarns which inhales snapped threads generated during the spinning, and drawn by use of a supplying roller 6 at a rate of 650 to 850 m/min and a temperature of 45 to 80° C. and a drawing roller 7 at a rate of 1500 to 4000 m/min and a temperature of 140 to 180° C.
  • Filaments are crimped at 180 to 220° C. under 5 to 8 kg/m 2 through a bulking unit 8 with a texturing nozzle after filaments are passed through the drawing roller 7 , and crimp is 10 to 60%.
  • filaments are cooled through a cooling drum 9 at 15 to 22°C., and twists and knots of 10 to 40 times/m are endowed to yarns under 4.5 to 5.0 kg/m 2 through a whirling machine 11 via a godet roller 10 , and so yarns are highly condensed.
  • whirling of 10 times/m or less is endowed to yarns, problems of fluffiness or capillaries occur because a grey yarn is poorly condensed, and so cutting efficiency of the grey yarn is reduced during the tufting, thereby a sheared carpet has a bad appearance because the edges of pile are frayed, and a bearing strength of the carpet is also lowered.
  • a speed of the wind-up machine 14 is determined according to the speed of the fifth godet roller 12 , and preferably 1400 to 3500 m/min.
  • the poly(trimethylene terephthalate) carpet of the present invention may be produced from a dope dyed yarn according to uses of the carpet.
  • the dope dyed yarn has excellent stain-resistance and resistance to wear, and can be applied to carpets for use in an office. But, carpets subjected to a piece dyeing can be suitably applied to high quality carpets for using in home or hotel.
  • a method for preparing a carpet from poly(trimethylene terephthalate) dope dyed yarns according to the present invention is the same as the method for preparing a carpet from general poly(trimethylene terephthalate) yarns as described above, except that a color master batch of 2 to 5% based on a base chip is blended with raw materials, and they are spun.
  • the carpet thus produced has more excellent color fastness to washing, color fastness to light, and color fastness to rubbing than the carpet subjected to piece dyeing, and a defective proportion is low because streaking hardly occurs.
  • the poly(trimethylene terephthalate) yarns of the present invention are subjected to post-processes such as cabling, heat setting, tufting, dyeing, becking, and shearing to prepare a carpet.
  • FIG. 3 a flow chart schematically illustrates a production process of the poly(trimethylene terephthalate) carpet according to the present invention.
  • Yarns are twisted in the step of cabling (S 1 ).
  • the yarns are S- or Z-twisted at 180 to 250 twists/m to two- or three-ply cables.
  • the RPM of the twister is preferably in the range of 4000 to 4300.
  • the twisted yarns are heat set (S 2 ).
  • a heat setting device may be Autoclave, Seussen, or Superbar. According to the present invention, Superbar is used.
  • the twisted yarns with a density of 200 to 240 g/m are preferably heat set at a main tunnel temperature of 120 to 160° C. and a band speed of 4 to 9 m/min with the use of steam.
  • the step of heat setting may further comprise Frieze-processing before setting with the use of steam, thereby the carpet has a three-dimensional appearance and two different colors effect having a positive aesthetic appeal, and also setting property and resistance to wear of pile are increased, as well as volume sense is improved.
  • yarns may be twisted to two- or three-ply cables with the use of an intermingle machine at 400 to 1000 m/min under 4 to 8 bar according to uses of carpets. After that, the yarns are tufted without heat setting.
  • heat-set yarns are planted on a PET spun bond or PP foundation cloth with the use of a tufting machine of 1 ⁇ 8, ⁇ fraction (5/32) ⁇ , and ⁇ fraction (1/10) ⁇ gauge (S 3 ).
  • a range of stitch is 5 to 15 stitches/inch.
  • a pile height ranges from 4 to 18 mm for a cut pile style carpet and from 2.5 to 15 mm for a loop pile style carpet.
  • a weight of the grey yarn used to produce a carpet ranges from 10 to 90 oz/yd 2 .
  • the weight and volume sense are poor at 5 stitches/inch or less.
  • drawing and peeling strengths are drastically reduced because yarns are not uniformly adhered to the foundation cloth during becking.
  • a tufted carpet is beck dyed without carriers by use of a disperse dye under conditions of atmospheric pressure and a dyeing temperature of 90 to 100° C. (S 4 ).
  • a disperse dye under conditions of atmospheric pressure and a dyeing temperature of 90 to 100° C.
  • the temperature is less than 90° C.
  • the carpet with desirable colors cannot be prepared because yarns are thin dyed.
  • OWF an amount of an added dye based on the carpet
  • a liquid ratio is 10:1 to 25:1
  • an amount of a dispersing agent ranges from 0.25 to 1.0 g/l.
  • Another dyeing method space dyeing, may be used, in which poly(trimethylene terephthalate) yarns are dyed with the use of a MCD (multi color dyeing) machine in a single color or in six or fewer colors before heat-setting.
  • MCD multi color dyeing
  • the dyed carpet is beck coated with latex so that piles do not came off, followed by being adhered to a second foundation cloth such as jute and polypropylene foundation cloth, and PVC or SBS (styrene butadiene styrene) is used as an auxiliary mat, i.e. a becking reinforcement.
  • Latex comprises solids of 80%, in detail, base latex of 30 to 50%, CaCO 3 of 50 to 70%, dispersing agent, and viscosity enhancing agent. To increase a reserve effect, small amount of Al 2 O 3 or Al 2 OH 3 may be added to latex.
  • piles are uniformly trimmed with the use of a spiral knife in the final step of shearing (S 6 ).
  • a poly(trimethylene terephthalate) carpet according to the present invention has excellent appearance, sense of touch, resistance to wear, and elastic recovery, which are advantages of nylon, as well as good stain-resistance and electrostatic resistance, which are advantages of polyester.
  • the poly(trimethylene terephthalate) carpet according to the present invention has compressibility of 30% or more, compressive resilience of 90% or more, pile yarns with drawing strength of 2.0 kg or more, bonded fabric with peeling strength of 2.0 kg or more, and color fastness to washing, color fastness to rubbing, and color fastness to light of 4 grade or more. Accordingly, the poly(trimethylene terephthalate) carpet according to the present invention is useful as a high quality carpet for use in home or office.
  • Pencil point was estimated in three grades, i.e. A: good, B: medium, C: bad, by observing with the naked eye a degree that the edges of pile was frayed;
  • Streak property was estimated in three grades, i.e. A: good, B: medium, C: bad, by the naked eye.
  • PTT polymer with a moisture regain of 40 ppm and an intrinsic viscosity of 0.92 was melt-spun at 250° C. with the use of a nozzle having a Y-shaped cross section, 68 holes, a modification ratio of 2.0, and an arm angle of 33° in a barmag spinning machine, which could produce three tons of spun yarns per day, to produce 68 filaments of 1300 deniers. Then, the resulting filaments were cooled to 16° C. in a cooling zone, at a velocity of 0.5 m/min. After that, the cold filaments were drawn by use of a supplying roller with a temperature of 60° C. and a speed of 700 m/min, and a drawing roller with a temperature of 160° C. and a speed of 2300 m/min.
  • the resulting BCF yarns were Z-twisted at 194 twists/m, followed by heat-setting the twisted yarns by a Superba unit. Twisted yarns with a density of 240 g/m were heat set at a main tunnel temperature of 138° C. and a band speed of 5.14 m/min (6 m/70 sec). The heat-set yarns were then planted on polypropylene foundation cloth with the use of a tufting machine with a ⁇ fraction (1/10) ⁇ gauge. The pile was of a cut pile style with a height of 12 mm, 13 stitches/inch, and a grey yarn weight of 4 kg/3.3 m 2 .
  • a tufted carpet was beck-dyed without carriers by use of a disperse dye DIANIX combi under conditions of atmospheric pressure, a dyeing temperature of 98° C., a dispersing agent of 0.5 g/l, OWF (an amount of an added dye based on the carpet) of 0.01%, and a liquid ratio of 20:1.
  • the dyed carpet was coated with a mixture of base latex of 35%, CaCO 3 of 60%, dispersing agent, and viscosity enhancing agent, followed by being adhered to a second foundation cloth, i.e. jute, and finally sheared with the use of a spiral knife.
  • the resulting carpet was evaluated in terms of appearance, pencil point, and color fastness to rubbing. The results are described in Table 2.
  • the carpet of example 1 had excellent appearance and color fastness to rubbing of grade 5 , and the edges of pile were not frayed. On the whole, carpets according to examples 2 and 3 also had excellent physical properties.
  • example 1 To test drawing and peeling strengths of piles varied according to an interval between stitches during tufting, the exact procedure of example 1 was repeated in example 5. In case of comparative examples 5 and 6, the procedure of example 1 was repeated except that heat-set yarns were planted on polypropylene foundation cloth at 3 stitches/inch and 20 stitches/inch, respectively.
  • the dope dyed BCF carpet of example 6 had more excellent color fastness to washing, color fastness to light, and color fastness to rubbing than the carpet subjected to a piece dyeing, and had slightly better streak property than example 1, so that dyed appearance of the dope dyed carpet was better than that of the general carpet. But, the dope dyed carpet was slightly poor in compressibility and compressive resilience because a dyeing step was absent and a growth of a latent bulk owing to the dyeing step was also absent. However, compressibility and compressive resilience of the dope dyed carpet according to the present invention were better than those of nylon or poly(ethylene terephthlate) carpet.
  • the present invention provides a poly(trimethylene terephthalate) carpet having excellent appearance, sense of touch, resistance to wear, elastic recovery, stain-resistance, electrostatic resistance, as well as peeling strength, drawing strength, and dimensional stability. Furthermore, the method for preparing poly(trimethylene terephthalate) carpet according to the present invention has an advantage of excellent post-process efficiency.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Carpets (AREA)
  • Artificial Filaments (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
US10/077,310 2001-05-14 2002-02-15 Method for preparing poly (trimethylene terephthalate) carpet Abandoned US20020197444A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/777,319 US20040161582A1 (en) 2001-05-14 2004-02-12 Method for preparing poly (trimethylene terephthalate) carpet
US11/082,581 US20050160570A1 (en) 2001-05-14 2005-03-17 Method for preparing poly (trimethylene terephthalate) carpet

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR10-2001-0026144A KR100397620B1 (ko) 2001-05-14 2001-05-14 폴리(트리메틸렌 테레프탈레이트) 카페트의 제조방법
KR2001-26144 2001-05-14

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/777,319 Division US20040161582A1 (en) 2001-05-14 2004-02-12 Method for preparing poly (trimethylene terephthalate) carpet

Publications (1)

Publication Number Publication Date
US20020197444A1 true US20020197444A1 (en) 2002-12-26

Family

ID=19709439

Family Applications (2)

Application Number Title Priority Date Filing Date
US10/077,310 Abandoned US20020197444A1 (en) 2001-05-14 2002-02-15 Method for preparing poly (trimethylene terephthalate) carpet
US10/777,319 Abandoned US20040161582A1 (en) 2001-05-14 2004-02-12 Method for preparing poly (trimethylene terephthalate) carpet

Family Applications After (1)

Application Number Title Priority Date Filing Date
US10/777,319 Abandoned US20040161582A1 (en) 2001-05-14 2004-02-12 Method for preparing poly (trimethylene terephthalate) carpet

Country Status (7)

Country Link
US (2) US20020197444A1 (zh)
JP (1) JP2002345623A (zh)
KR (1) KR100397620B1 (zh)
CN (1) CN1385574A (zh)
BE (1) BE1014787A3 (zh)
DE (1) DE10221374A1 (zh)
TW (1) TWI220431B (zh)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040099984A1 (en) * 2002-11-21 2004-05-27 Jing-Chung Chang Polyester bicomponent filament
US20050147784A1 (en) * 2004-01-06 2005-07-07 Chang Jing C. Process for preparing poly(trimethylene terephthalate) fiber
US20080014403A1 (en) * 2006-07-13 2008-01-17 Chang Jing C Substantially Flame Retardant-Free 3GT Carpet
CN109112647A (zh) * 2018-09-29 2019-01-01 浙江工业大学之江学院 一种制吸油毛毡用异形纤维的加工工艺

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100419336B1 (ko) * 2001-12-12 2004-02-21 도레이새한 주식회사 우수한 광택과 부드러운 촉감을 갖는 폴리에스테르이형단면사의 제조방법과 이를 이용하여 제편한 기모성경편직물
KR100415731B1 (ko) * 2001-12-27 2004-01-24 주식회사 효성 폴리트리메틸렌테레프탈레이트 벌키 연속 필라멘트 및카페트의 제조방법
JP2005264408A (ja) * 2004-03-22 2005-09-29 Honda Motor Co Ltd 車両用表皮材及びその製造方法、自動車用内装材及び自動二，三輪車用シート材
DE102007006759A1 (de) * 2007-02-12 2008-08-14 Carl Freudenberg Kg Verfahren zur Herstellung eines getufteten Vliesstoffes, getufteter Vliesstoff und dessen Verwendung
DE102007006760B3 (de) * 2007-02-12 2008-08-21 Carl Freudenberg Kg Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung
CN113388962A (zh) * 2021-07-15 2021-09-14 江阴市华思诚无纺布有限公司 一种柔软服贴型自粘类防水卷材用非织造布及生产方法
CN115341290A (zh) * 2022-09-21 2022-11-15 苏州斯宾耐特化纤科技有限公司 一种弹性纤维的喷丝板及其制造工艺

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3998042A (en) * 1972-09-26 1976-12-21 E. I. Du Pont De Nemours And Company Mixed shrinkage yarn
US4877572A (en) * 1988-07-12 1989-10-31 Davy Mckee Aktiengesellschaft Process for the production of PBT carpet yarn
US5160347A (en) * 1990-10-05 1992-11-03 Burlington Industries, Inc. Multicolored piece-dyed rugs
US5325301A (en) * 1991-07-17 1994-06-28 E. I. Du Pont De Nemours And Company Method of analyzing the texture of a surface and a carpet characterized by the method
US5662900A (en) * 1992-11-24 1997-09-02 Institut Pasteur De Kyoto Method of increasing interferon production in humans
US5662980A (en) * 1994-06-30 1997-09-02 E.I. Du Pont De Nemours And Company Carpets made from poly(trimethylene terephthalate) bulked continuous filaments
US5958548A (en) * 1996-08-14 1999-09-28 Nyltec Inc. Carpet tufted with bulked continuous filament carpet face yarns utilizing new sheathed core filaments and related selection techniques to produce cost savings
US6109015A (en) * 1998-04-09 2000-08-29 Prisma Fibers, Inc. Process for making poly(trimethylene terephthalate) yarn
US6315934B1 (en) * 1995-05-08 2001-11-13 Shell Oil Company Process for preparing poly(thimethylene therephthalate) carpet yarn
US20020012763A1 (en) * 1995-05-08 2002-01-31 Chuah Hoe Hin Process for preparing poly(trimethylene terephthalate) carpet yarn
US20030045611A1 (en) * 2001-06-29 2003-03-06 Agarwal Nirmal K. Process for preparing pigmented shaped articles comprising poly (trimethylene terephthalate)

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2250671B1 (zh) * 1973-11-09 1980-01-04 Aerospatiale
US4492731A (en) * 1982-11-22 1985-01-08 E. I. Du Pont De Nemours And Company Trilobal filaments exhibiting high bulk and sparkle
CZ161992A3 (en) * 1991-05-31 1993-12-15 Basf Corp Filament of a hollow three-lobe cross-section and a plate-like spinning nozzle for producing thereof
JPH05146350A (ja) * 1991-10-19 1993-06-15 Negi Sangyo Kk カツトパイルタフテツドカーペツト
JPH07324275A (ja) * 1994-05-31 1995-12-12 Unitika Ltd カットパイルカーペット及びその製造方法
US5567256A (en) * 1994-12-21 1996-10-22 Burlington Industries, Inc. Process of making cotton room-size rugs
JPH10323270A (ja) * 1997-03-24 1998-12-08 Toray Ind Inc 多杢調カーペットおよびその製造方法

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3998042A (en) * 1972-09-26 1976-12-21 E. I. Du Pont De Nemours And Company Mixed shrinkage yarn
US4877572A (en) * 1988-07-12 1989-10-31 Davy Mckee Aktiengesellschaft Process for the production of PBT carpet yarn
US5160347A (en) * 1990-10-05 1992-11-03 Burlington Industries, Inc. Multicolored piece-dyed rugs
US5325301A (en) * 1991-07-17 1994-06-28 E. I. Du Pont De Nemours And Company Method of analyzing the texture of a surface and a carpet characterized by the method
US5662900A (en) * 1992-11-24 1997-09-02 Institut Pasteur De Kyoto Method of increasing interferon production in humans
US5662980A (en) * 1994-06-30 1997-09-02 E.I. Du Pont De Nemours And Company Carpets made from poly(trimethylene terephthalate) bulked continuous filaments
US6242091B1 (en) * 1994-06-30 2001-06-05 E. I. Du Pont De Nemours And Company Yarns comprised of bulked continuous filaments of poly(trimethylene terephthalate)
US6315934B1 (en) * 1995-05-08 2001-11-13 Shell Oil Company Process for preparing poly(thimethylene therephthalate) carpet yarn
US20020012763A1 (en) * 1995-05-08 2002-01-31 Chuah Hoe Hin Process for preparing poly(trimethylene terephthalate) carpet yarn
US5958548A (en) * 1996-08-14 1999-09-28 Nyltec Inc. Carpet tufted with bulked continuous filament carpet face yarns utilizing new sheathed core filaments and related selection techniques to produce cost savings
US6109015A (en) * 1998-04-09 2000-08-29 Prisma Fibers, Inc. Process for making poly(trimethylene terephthalate) yarn
US20030045611A1 (en) * 2001-06-29 2003-03-06 Agarwal Nirmal K. Process for preparing pigmented shaped articles comprising poly (trimethylene terephthalate)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040099984A1 (en) * 2002-11-21 2004-05-27 Jing-Chung Chang Polyester bicomponent filament
US20050147784A1 (en) * 2004-01-06 2005-07-07 Chang Jing C. Process for preparing poly(trimethylene terephthalate) fiber
US20080014403A1 (en) * 2006-07-13 2008-01-17 Chang Jing C Substantially Flame Retardant-Free 3GT Carpet
WO2008020933A3 (en) * 2006-07-13 2008-04-24 Du Pont Substantially flame retardant-free 3gt carpet
US8021736B2 (en) 2006-07-13 2011-09-20 E.I. Du Pont De Nemours And Company Substantially flame retardant-free 3GT carpet
CN109112647A (zh) * 2018-09-29 2019-01-01 浙江工业大学之江学院 一种制吸油毛毡用异形纤维的加工工艺

Also Published As

Publication number Publication date
KR20020087159A (ko) 2002-11-22
CN1385574A (zh) 2002-12-18
US20040161582A1 (en) 2004-08-19
DE10221374A1 (de) 2002-11-28
JP2002345623A (ja) 2002-12-03
TWI220431B (en) 2004-08-21
KR100397620B1 (ko) 2003-09-13
BE1014787A3 (fr) 2004-04-06

Similar Documents

Publication Publication Date Title
US6129879A (en) Propylene polymer fibers and yarns
US5945215A (en) Propylene polymer fibers and yarns
EP0767846B1 (en) Process for making poly(trimethylene terephthalate) bulked continuous filaments, the filaments thereof and carpets made therefrom
US20020197444A1 (en) Method for preparing poly (trimethylene terephthalate) carpet
US6627310B2 (en) Poly(trimethylene terephthalate) BCF carpet yarn with noncircular cross section and method for preparing the same
TWI868270B (zh) 由自膨化性含ｐｔｔ之雙組分纖維製成的地毯及生產地毯的改進之方法
EP0706586B1 (en) Multifilament yarn comprising filaments of bilobal cross section, carpets prepared therefrom having a silk-like luster and soft hand and spinneret
KR100415731B1 (ko) 폴리트리메틸렌테레프탈레이트 벌키 연속 필라멘트 및카페트의 제조방법
US20050160570A1 (en) Method for preparing poly (trimethylene terephthalate) carpet
KR20230022889A (ko) 2성분 섬유의 제조 방법 및 이를 포함하는 물품
US6136436A (en) Soft silky large denier bicomponent synthetic filament
KR100859085B1 (ko) 폴리에스테르 혼섬사 및 그 제조방법
CN108103690A (zh) 一种超强吸水高弹蓬松雪尼尔面料的制备方法
JPH09273025A (ja) ポリエステル捲縮糸、立毛布帛および立毛布帛の製造方法

Legal Events

Date Code Title Description
AS Assignment

Owner name: HYOSUNG CORPORATION, KOREA, REPUBLIC OF

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LEE, KYOOL SEOP;CHOI, YOUNG CHAN;LEE, JONG BOK;REEL/FRAME:012611/0485

Effective date: 20020205

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION