JP4789261B2 - Breathable tile carpet with improved vegetation - Google Patents

Description

  The present invention relates to a tile carpet using yarns made from plant-derived materials as pile yarns. More specifically, a plant having excellent volume and texture, and excellent wear resistance by using, as a pile yarn, an original polylactic acid crimped yarn having excellent bulkiness, high toughness and excellent wear resistance, etc. A tile carpet with an improved degree is obtained.

  Polylactic acid is a biodegradable resin that uses lactic acid obtained from starch such as corn as a raw material, and since it uses plants as a raw material, it is effective in reducing carbon dioxide, a possible cause of global warming. It is attracting attention as a material that is friendly to the global environment. However, carpets using conventional polylactic acid fibers as pile yarns have the disadvantages that they are inferior in bulkiness, easy to wear and easy to wear, and have been put to practical use only for limited applications. This is because the yarn physical properties such as strength and elongation of polylactic acid crimped yarn made from plant-derived materials and its crimp characteristics are inferior to nylon, polypropylene and polyester fiber crimped yarns made from petroleum-derived materials. If the same physical properties as the current nylon, polypropylene, and polyester fiber crimped yarns can be obtained, the polylactic acid crimped yarn made from plant-derived materials is widely used as a material that is friendly to the global environment for carpets and other interiors. Expected to expand.

  As conventional techniques, Patent Document 1, Patent Document 2, and Patent Document 3 are disclosed regarding carpets using polylactic acid crimped yarns and methods for producing the carpets.

  Patent Document 1 aims to provide “a tufted carpet base fabric that does not cause a problem in the natural environment when it becomes unnecessary, and a tufted carpet using this base fabric”. “The tufted carpet base fabric is composed of a long-fiber nonwoven fabric formed of a polylactic acid polymer, and the pile yarn formed of the polylactic acid polymer is tufted to the base fabric. And is formed of a material having biodegradability as a backing material. ”, Specifying physical properties such as the cross-sectional shape, birefringence, and crystallinity of the long-fiber nonwoven fabric, It describes a tufted carpet in which the pile yarn used for the carpet is specified by a polylactic acid-based polymer and a material whose backing material is biodegradable.

  Patent Document 2 has an object of “providing a biodegradable carpet in harmony with the environment.” As a means for solving the problem, “having a bulkiness suitable for use on carpet and providing biodegradability. Using a biodegradable fiber as a pile and further using a biodegradable material as a base fabric and a backing material. ”, Using an aliphatic polyester, particularly polylactic acid, Describes biodegradable carpets that identify yarns, fabrics and backing films.

  Patent Document 3 states that “When landfilled, it decomposes and disappears naturally in the ground, and no harmful gas is generated even when incinerated, and it can be easily disposed of, such as low combustion heat. "Provide carpets." As a means for solving the problem, "ply yarn, ground yarn and other yarns and base fabric, lining and other fabrics are made of polylactic acid resin fibers, and the base fabric and the lining are joined. "Use of a polylactic acid resin composition for the adhesive layer" is disclosed, and a carpet having a polylactic acid resin fiber yarn and cloth as a configuration and a polylactic acid resin composition as an adhesive is described.

  The technique of the above-mentioned patent document 1 uses a long fiber nonwoven fabric using a polylactic acid polymer as a base fabric, a biodegradability using a polylactic acid polymer as a pile yarn and a biodegradable material as a backing material. It mentions carpet. However, the durability such as wear resistance and bulkiness of the carpet produced from the polylactic acid polymer is not mentioned.

  The technique of the above-mentioned patent document 2 refers to a biodegradable carpet using aliphatic polyester, particularly polylactic acid. Although the covering property and the harshness of the carpet manufactured from the polylactic acid resin fiber are described, the durability such as the abrasion resistance and the settling resistance of the carpet is not described at all.

  Moreover, the technique of the said patent document 3 mentions the carpet using the fiber of polylactic acid resin, and its adhesive agent, especially a biodegradable carpet. However, there is no mention of durability such as abrasion resistance and sag resistance of carpets made from polylactic acid resin fibers.

  Since the contents of the above Patent Documents 1 to 3 do not refer to the durability of the carpet, such as wear resistance and bulkiness and sag resistance, the wear resistance of the carpet obtained by the technique, It cannot be said that the level of durability such as bulkiness and anti-sagging is at a satisfactory level.

Republished patent WO00 / 65140 JP 2002-2448047 A JP 2003-10030 A

  The object of the present invention is to overcome the problems of durability such as abrasion resistance, bulkiness and sag resistance of carpet made of polylactic acid resin, and use original polylactic acid crimped yarn as a pile that could not be achieved by the conventional technology It is in providing a breathable tile carpet. That is, using an original polylactic acid crimped yarn excellent in bulkiness, high toughness and abrasion resistance as a pile, using a cushioned non-woven fabric as a backing layer, and heat as an adhesive resin layer By using a plastic resin powder, it is an object to provide a breathable tile carpet which is excellent in volume and texture, is excellent in abrasion resistance and has an improved plant degree.

  The present invention can be achieved by the following means in order to solve the above problems.

[1] Original polylactic acid in which a cross-sectional shape of a single fiber is at least a circular shape or a circular shape as a pile yarn in a tile carpet composed of a skin layer composed of a pile yarn and a base fabric, an adhesive resin layer, and a backing layer A breathable tile carpet with improved plantiness, comprising crimped yarns, wherein the adhesive resin layer is made of thermoplastic resin powder, and the backing layer is made of a cushioned nonwoven fabric.

[2] The plant degree according to item 1 above, wherein the original polylactic acid crimped yarn contained in at least the pile yarn of the skin layer simultaneously satisfies the following characteristics (1) to (7): Improved breathable tile carpet.
(1) The cross-sectional shape of the single fiber is substantially circular or circular, and the degree of profile expressed by the ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the fiber cross section Is less than 1.5 (2) Relative viscosity (RV) 2.5-3.8
(3) Strength 1.75 to 3.5 cN / dtex
(4) Elongation is 35-60%
(5) Single yarn fineness is 2.5-25 dtex
(6) Hot water shrinkage 2-8%
(7) Dry heat crimp rate is 5-25%

[3] The tile carpet skin layer containing at least the original polylactic acid crimped yarn as a pile yarn has an abrasion amount of the pile yarn according to a Taber type abrasion test (wear wheel: H-18, number of wear 2,500 times). 3. A breathable tile carpet with improved plantiness according to item 1 or 2, characterized by being 5 to 30% by weight.

[4] The backing layer is a backing layer in which a latex or a resin emulsion is applied from 200 to 300 g / m ² (during drying) from the lower surface side of the cushioning nonwoven fabric, and the cushioning property is left on the upper surface side. 4. The air permeable tile carpet having improved plantiness according to any one of items 1 to 3 above.

  In the invention of [1], since the cross-sectional shape of the single fiber constituting the original polylactic acid crimped yarn is a substantially circular shape or a circular shape, a tile carpet skin layer having excellent wear resistance can be obtained. Also, because it is an original polylactic acid crimped yarn, there is no need to provide a dyeing process with heat treatment in the carpet manufacturing process, and adverse effects (such as a decrease in mechanical strength) due to heat treatment can be avoided, and it has high toughness and wear resistance It can be made into the carpet with the improved plant degree excellent in the property. In addition, since the thermoplastic resin powder is used for the adhesive resin layer, when the thermoplastic resin powder is heated and melted to bond the skin layer and the backing layer, the adhesive resin layer becomes air permeable and has air permeability. It can be a tile carpet and can be used as a tile carpet for underfloor air conditioning. Moreover, since the cushioning nonwoven fabric is used as the backing layer, damage to the skin layer can be suppressed lower than when a vinyl chloride or non-vinyl chloride resin is used as the backing layer, and the weight can be reduced.

  In the invention of [2], the cross-sectional shape and irregularity of the single fiber constituting the original polylactic acid crimped yarn are limited to a specific configuration, the relative viscosity is limited to a specific range, and the strength, elongation and single yarn are Since the fineness, the hot water shrinkage rate, and the dry heat crimp rate are limited to specific ranges, respectively, a tile carpet having excellent bulkiness, high toughness, and excellent wear resistance can be obtained.

  In the invention of [3], the amount of wear of the pile yarn is 5 by the Taber type abrasion test (wear wheel: H-18, number of wear 2,500 times) of the carpet skin using the pile yarn of the original polylactic acid crimped yarn. Since it is -30 weight%, it can be set as the carpet excellent in abrasion resistance.

In the invention of [4], the latex or resin emulsion is applied from 200 to 300 g / m ² (when dry) from the lower surface side of the nonwoven fabric having cushioning properties, so that a tile carpet having a firm waist can be obtained, Since the cushioning property remains, cushioning property is imparted to the skin layer, and a skin layer with improved durability such as wear resistance and sag resistance can be obtained. In addition, when installing this tile carpet, the amount of adhesive used to bond the flooring and tile carpet is prevented from being impregnated into the nonwoven fabric by the latex or resin emulsion coating layer. The amount can be saved.

  The present invention has been intensively studied to improve poor wear resistance and lack of bulkiness of tile carpets using original polylactic acid crimped yarns made of plant-derived materials as pile yarns, and the original poly used for pile yarns The cross-sectional shape and relative viscosity (RV), strength, elongation, single yarn fineness, hot water shrinkage rate, dry heat crimp rate, etc. of the single fiber itself of the lactic acid crimped yarn are limited to specific ones. When the backing layer was made of a cushioned nonwoven fabric, it was possible to provide a carpet with improved plantiness that could solve the above-mentioned problems all at once.

  FIG. 1 is a schematic view of a tile carpet 101 of the present invention. The skin layer 104 in which the pile yarn 102 is planted on the base fabric 103 is bonded to the backing layer 105 through the adhesive resin layer 106.

  In the present invention, the original polylactic acid crimped yarn made of a plant-derived raw material constituting at least the pile yarn 102 is a crimped yarn obtained by producing a specific polylactic acid polymer and crimping it, and has fiber characteristics. Although the pile yarn is limited to a specific one, the method for manufacturing the carpet is not particularly limited, and examples thereof include a method for manufacturing a woven carpet, an embroidery carpet, an adhesive carpet, a knitted carpet, and the like. The form of the pile is not particularly limited, and any form of cut pile, loop pile, and cut and loop can be selected.

  The polylactic acid polymer constituting the polylactic acid composition that is a raw material for the original polylactic acid crimped yarn is polylactic acid obtained by polymerizing a lactic acid monomer mainly composed of L-lactic acid. It is preferable to adopt a configuration in which 90% by mass or more of the lactic acid monomer is composed of L-lactic acid. That is, the lactic acid monomer may contain D-lactic acid within a range not exceeding 10% by mass. If the optical purity of the lactic acid monomer used (the optical purity of the L form) is 90% or higher, the polymer (polylactic acid) is preferably crystalline, and if the optical purity of the lactic acid monomer used is 97% or higher, the melting point Is more preferably around 170 ° C. Moreover, as long as the effect of this invention is not impaired, what copolymerized components other than lactic acid may be used.

The cross-sectional shape of the constituent single fiber is substantially circular or circular (that is, round cross-section yarn). Such a cross-sectional shape makes it difficult to rub even if there is friction or the like. It is preferable that the profile is a substantially circular shape or a circular shape having an irregularity expressed by a ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the fiber cross section. (See Fig. 2) When the degree of deformity exceeds 1.5, the covering characteristics of the polylactic acid crimped yarn will be improved, but since the degree of deformity is high, the hard and brittle properties of polylactic acid are likely to occur and the wear resistance of the yarn This is not preferable because the properties are lowered.

The relative viscosity (RV) of the original polylactic acid crimped yarn needs to be 2.5 to 3.8. Here, the relative viscosity is a value measured with a mixed solution of 20 ° C. and phenol / tetrachloroethane = 60/40 (mass ratio). When the relative viscosity is less than 2.5, the strength and elongation of the polylactic acid crimped yarn and wear resistance suitable for carpet use cannot be imparted. On the other hand, when the relative viscosity is higher than 3.8, the melt viscosity becomes too high, and as a result, it is necessary to increase the spinning temperature. As a result, the relative viscosity of the polylactic acid crimped yarn obtained before melting is increased. The level is lower than the level, and the strength is not sufficiently improved, and it becomes difficult to produce the yarn. Among them, the relative viscosity of the original polylactic acid crimped yarn is preferably 2.8 to 3.6.

  The strength of the original polylactic acid crimped yarn is 1.75 to 3.5 cN / dtex. When the strength of the crimped yarn is less than 1.75 cN / dtex, the wear resistance is inferior when the tile carpet is used, and a portion of the crimped yarn may be worn out during use. Among them, the strength of the original polylactic acid crimped yarn is preferably 2.0 to 3.25 cN / dtex, more preferably 2.25 to 3.25 cN / dtex. The elongation of the original polylactic acid crimped yarn is 35 to 60%. When the elongation of the crimped yarn is less than 35%, the wear resistance is inferior when the carpet is used, and a portion of the crimped yarn may be worn out during use. Among them, the elongation of the original polylactic acid crimped yarn is preferably 40 to 55%.

  When the strength of the original polylactic acid crimped yarn is 2.0 to 3.25 cN / dtex and the elongation of the original polylactic acid crimped yarn is 40 to 55%, higher toughness is obtained. Therefore, it is preferable. However, as the strength is increased, the normal elongation decreases. When the elongation is 35% or more, the strength is 3.5 cN / dtex at the most, and when the elongation exceeds 60%, the strength is decreased. It cannot be 1.75 cN / dtex or more.

  The total fineness of the original polylactic acid crimped yarn is preferably in the range of 500 to 3,500 dtex. If it is such a range, it will become an original crimped yarn best suited for a tufted carpet use. Among them, the total fineness of the original polylactic acid crimped yarn is preferably in the range of 1,000 to 3,000 dtex. Further, the single yarn fineness of the original polylactic acid crimped yarn is in the range of 2.5 to 25 dtex. When the single yarn fineness is less than 2.5 dtex, it is difficult to stably produce the crimped yarn, and the carpet formed using the crimped yarn has insufficient bulkiness. On the other hand, if the single yarn fineness exceeds 25 dtex, it is difficult to obtain the yarn physical properties of the original polylactic acid crimped yarn, and the polylactic acid is likely to be hard and brittle. The constructed carpet has insufficient wear resistance. This tendency becomes prominent when the degree of irregularity of the cross-sectional shape of the polylactic acid fiber is increased at the same single yarn fineness. Therefore, it is preferable that the degree of deformity of the single fiber is small. Among them, the single yarn fineness of the original polylactic acid crimped yarn is in the range of 4 to 20 dtex, more preferably 5 to 15 dtex. In addition, within the range of the single yarn fineness of 2.5 to 25 dtex, as the single yarn fineness is reduced, the property that the polylactic acid is hard and brittle is reduced, and the strength and elongation of the original polylactic acid crimped yarn are further improved. In addition, it is possible to improve the wear resistance of the carpet.

  The hot-water shrinkage rate of the original polylactic acid crimped yarn is in the range of 2 to 8%. When the hot water shrinkage is less than 2%, the polylactic acid crimped yarn has a high degree of crystallinity, and the polylactic acid is hard and brittle, and the strength and elongation are not well-balanced. Wear resistance is not good. On the other hand, when the hot water shrinkage rate exceeds 8%, there is a problem that yarn shrinkage occurs at the time of heat setting treatment of the polylactic acid crimped yarn, and it becomes difficult to manage in each process in carpet manufacture. Among them, the hot water shrinkage rate of the original polylactic acid crimped yarn is preferably in the range of 3 to 6%.

  Further, the dry heat crimp rate of the original polylactic acid crimped yarn is in the range of 5 to 25%. This dry heat crimp rate is a parameter indicating the bulkiness of the original polylactic acid crimped yarn, and the original polylactic acid crimped yarn is treated with hot air at 100 ° C. to develop the crimp. It is a value indicating the degree. When the dry heat crimp rate is less than 5%, the crimp is insufficient, the bulkiness as the carpet is insufficient, and the settling resistance is inferior. On the other hand, a carpet composed of polylactic acid crimped yarn having a dry heat crimp rate exceeding 25% is felt-like, and a preferable carpet cannot be obtained. Among these, the dry heat crimp rate of the original polylactic acid crimped yarn is preferably in the range of 8 to 20%.

  Examples of the colorant used for the original polylactic acid crimped yarn include inorganic pigments and organic pigments, and are not particularly limited as long as they can give color to the crimped yarn. Examples of the colorant include carbon black, oxidized inorganic pigments, ferrocyanide inorganic pigments, silicate inorganic pigments, carbonate inorganic pigments, phosphate inorganic pigments, and the like, phthalocyanine organic pigments, perylene organic pigments, At least one pigment selected from the group consisting of isoindolinone-based organic pigments is used.

  The polylactic acid composition used as a raw material for the original polylactic acid crimped yarn preferably has a composition containing 0.01 to 3.0% by mass of a colorant. By setting to such a density | concentration, the color of a suitable density | concentration can be provided to a crimped yarn and the design property can be improved. Further, when the content is 0.01% by mass or more, the occurrence of uneven color due to pigment unevenness can be prevented, and when the content is 3.0% by mass or less, occurrence of yarn breakage during yarn production can be sufficiently prevented. . Among them, the content of the colorant is preferably 0.05 to 1.0% by mass. The colorant can also be used in combination with a commonly used dispersant (such as an olefin compound).

  In addition, the polylactic acid composition includes a polymer (including polymer particles) other than polylactic acid, a matting agent, a plasticizer, a flame retardant, and an antistatic agent as long as the effects of the present invention are not impaired. Various additives such as an agent, a deodorant, an antibacterial agent, an antioxidant, a heat-resistant agent, a light-resistant agent, and an ultraviolet absorber may be contained as necessary.

  The pile yarn used for the carpet of the present invention may be a non-twisted yarn and / or a twisted yarn of only the original polylactic acid crimped yarn, and these are used as a single yarn and / or two or more twisted yarns. It can also be used in combination with other fibers or entangled with other fibers or twisted with other fibers. Alternatively, the skin layer may be formed by arranging the original polylactic acid crimped yarns and yarns of other fibers every other one.

  The pile yarn using the original polylactic acid crimped yarn is based on carpet production standards, and the pile yarn color, total fineness (dtex), polylactic acid crimped yarn state (non-twisted yarn or twisted yarn, etc.) Decide the number of crimped yarns and the condition and form of the twisted yarn.

  Next, the base fabric used for the tile carpet of the present invention is not particularly limited, and may be a commonly used fabric such as a woven base fabric or a nonwoven fabric.

  The skin layer using the original polylactic acid crimped yarn as a pile yarn is preferably subjected to a sealing treatment in order to fix the pile yarn to the base fabric. At this time, it will pass through a drying step and a heat setting step, and usually the crimping latent in the original polylactic acid crimped yarn is expressed by dry heat treatment and / or steam treatment, and is excellent in bulkiness. It can be set as a skin layer without a feeling of bottoming.

  Furthermore, the abrasion amount of the pile yarn by the Taber type abrasion test (wear wheel: H-18, number of abrasions 2,500 times) of the carpet skin layer of the present invention is 5 to 30% by weight. When the abrasion amount of the pile yarn according to the Taber type abrasion test is 5 to 30% by weight, a carpet having excellent abrasion resistance can be obtained. The pile yarn wear amount is preferably 5% by weight or less, but it is difficult to achieve in practice. When the wear amount of the pile yarn is 30% by weight or more, the fibers fall off with time while the carpet is used, and the carpet base fabric can be seen and the appearance changes greatly.

In order to bond the skin layer of the present invention and the backing layer made of a cushioning nonwoven fabric while maintaining air permeability, it is preferable to use thermoplastic resin powder as the adhesive resin layer. The thermoplastic resin powder is preferably a polyethylene resin powder having a particle size of 90 to 10,000 μm. A particle size of 100 to 500 μm is more preferable. As shown in FIG. 4, with the pile side of the skin layer 104 facing downward, the thermoplastic resin powder is sprayed on the superposed surface of the skin layer with the spraying device 107, and then the thermoplastic resin powder is heated with the heating device 108. The outer skin layer 104 and the backing layer 105 are bonded and integrated with each other through the air-permeable adhesive resin layer 106 by melting and then pressing in a state where the backing layer 105 made of non-woven fabric is superimposed thereon. is there. The spray amount of the thermoplastic resin powder is preferably 5 to 500 g / m ² . More preferably, it is 50-400 g / m < ² >.

Further, the backing layer of the present invention is a cushioning nonwoven fabric, and the constituent fibers are not particularly limited, but a felt-like needle punched nonwoven fabric is preferred. Moreover, it is preferable that it is a backing layer which apply | coated latex or resin emulsion 200-300 g / m < ² > (at the time of drying) from the lower surface side of the said nonwoven fabric. By applying the latex or the resin emulsion from the lower surface side, the lowermost layer of the backing layer becomes hard, and the waist as a tile carpet is imparted while maintaining air permeability. In order to provide dimensional stability of the tile carpet, it is preferable to insert and laminate a woven fabric, a nonwoven fabric, a braided fabric, or the like made of glass fiber or polyester fiber between the skin layer and the backing layer.

  The skin layer of the present invention contains at least the original polylactic acid crimped yarn in the pile yarn, but 30 to 70% by weight of polylactic acid resin can be added to the base fabric or backing resin constituting the carpet. For example, it is possible to obtain a carpet skin layer that is friendly to the global environment from the standpoint of environmental protection, with a further improvement in plantiness and less increase in carbon dioxide in the air.

  The physical property definitions and measurement methods described in the text and examples are as follows.

[Relative viscosity: RV]
The sample was dissolved in a mixed solution of phenol / tetrachloroethane = 60/40 (weight ratio) to a concentration of 1 g / dl, and the relative viscosity (RV) was measured at 20 ° C. using an Ubbelohde viscosity tube.

[Measurement of weight average molecular weight]
The sample was dissolved in chloroform to a concentration of 10 mg / ml. GPC analysis was performed with Tosoh HLC8120 GPC using chloroform as a solvent, and the weight average molecular weight Mw was measured. RI was used as a detector and polystyrene was used as a molecular weight standard.

[Measurement of L-lactic acid]
Polylactic acid was hydrolyzed, and the ratio of L-lactic acid was determined using high performance liquid chromatography (HPLC: LC10AD type, manufactured by Shimadzu Corporation) using methanolic sodium hydroxide solution 1.0N as a solvent.

[Strong elongation]
Strength (cN) and elongation (%) were measured under the conditions of a sample length of 25 cm and a tensile speed of 30 cm / min using a tensile tester of TENSORAPID3 manufactured by USTER.

  The strength (cN / dtex) is a value obtained by dividing the strength of the multifilament by its fineness.

[Fineness]
Measured according to JIS L 1013.

[Deformation degree]
After cutting the single yarn, the diameter (B) of the circumscribed circle of the single yarn and the diameter (A) of the inscribed circle were measured using an optical microscope, and obtained by the following formula.
Deformity = (B) / (A)

[Hot water shrinkage]
The hot water shrinkage (%) is a measured value according to JIS L1013 Kase shrinkage (Method A). A polylactic acid crimped yarn cut from a bobbin package is used as a sample. A load giving a tension of total fineness dtex × 0.882 mN (90 mg / dtex) is applied to the sample yarn, and after 10 seconds, the sample length (Ls1) is measured. After being immersed in hot water at 98 ° C. for 30 minutes in an unloaded state, it is naturally dried all day and night. This is the polylactic acid crimped yarn after the hot water treatment. A load giving the same total fineness dtex × 0.882 mN (90 mg / dtex) tension is applied to the sample yarn before the hot water treatment, and after 10 seconds, the sample length (Ls2) is measured. The hot water shrinkage rate (%) is obtained from the following formula.

  Hot water shrinkage (%) = [(Ls1-Ls2) / Ls1] × 100

[Dry heat crimp rate]
The polylactic acid crimped yarn cut from the bobbin package is treated with hot air at 100 ° C. for 10 minutes under no load, and then allowed to stand naturally for 10 minutes. This is the polylactic acid crimped yarn after the dry heat treatment. A constant load that gives a tension of total fineness dtex × 0.882 mN (90 mg / dtex) is applied to the sample yarn, and after 10 seconds, the sample length (Lc1) is measured. Next, a constant load that gives a tension of a total fineness of dtex × 0.0176 mN (1.8 mg / dtex) is applied to the sample, and after 10 minutes, the sample length (Lc2) is measured. The dry heat crimp rate (%) is obtained from the following formula.

  Dry heat crimp rate (%) = [(Lc1-Lc2) / Lc1] × 100

[Bulky]
When the carpet was viewed from directly above, it was visually evaluated in a state where the base fabric could be seen from the gap between the pile skins. Those that were not visible were marked with (◎), those that were difficult to see were marked with (○), those that were slightly visible were marked with (△), and those that were visible were marked with (x).

[Abrasion resistance]
The abrasion resistance of the carpet was in accordance with a Taber type abrasion tester (specified in JIS L 1096.17.3). Using a H-18 wear wheel, a load of 9.8 N was applied to each wear wheel, the test stand was rotated 2500 times to wear the test piece, and the wear state of the pile yarn was visually evaluated. Those with very little wear were marked with (◎), those with little wear (◯), those with some wear (△), and those with much wear (x).

<Example 1>
The production methods of the original polylactic acid crimped yarn, the pile yarn and the carpet were as follows, and the evaluation results are shown in Table 1.
[Manufacture of original polylactic acid crimped yarn]
An original polylactic acid crimped yarn was produced using a production apparatus having the structure shown in FIG. A polylactic acid chip (polymer of lactic acid monomers consisting of 98% by weight of L-lactic acid and 2% by weight of D-lactic acid. Weight average molecular weight: 140,000, relative viscosity: 3.2, melting point: Tm = 170 ° C.) While adding 100 parts by weight, while adding 4 parts by weight of carbon black 25% by weight kneading masterbatch made of the same polylactic acid resin from the additive inlet 11 and degassing with the twin screw extruder 12 Melt kneading was performed at 230 ° C. The content of carbon black as a colorant was 1.0% by weight.

  The spinning temperature of the spinning head 14 was 225 ° C., a 600 mesh filter was used for the spinning pack 15, polylactic acid resin was discharged from a nozzle having a circular section (round section) 64 holes, and three packs were spun together.

  The spun yarn was cooled and solidified with cold air (20 ° C. × 70%) of the spray cooling device 16 to obtain 192 polylactic acid multifilaments having a circular cross section (round cross section).

  The spinning yarn is cooled and solidified, and then a 15 wt% water emulsion type oil agent for polylactic acid yarn is applied by an oiling device 17 and wound around an unheated take-up roller 1 rotating at a speed of 423 m / min. It was. Then, the yarn was preheated by being preheated by the preheating roller 2 at a speed of 426 m / min heated to 70 ° C., and wound on the drawing roller 3 at a speed of 444 m / min at a temperature of 105 ° C. The film was stretched between the heat setting roller 4 heated to 123 ° C. rotating at 2,000 m / min. The draw ratio was 4.5 times.

  Next, the drawn yarn was guided to the heated fluid crimping device 5, crimped by 115 ° C. and 0.6 MPa heated air, and cooled on the cooling drum 20. Next, the polylactic acid crimped yarn was subjected to entanglement treatment of 32 pcs / m by the entanglement treatment device 21 and wound into a cheese 22 shape at a speed of 1,737 m / min with a winding tension of 0.05 cN / dtex. .

  The obtained black original polylactic acid crimped yarn has a circular cross section (round cross section) having a fineness of 1,674 dtex / 192 filament (single yarn fineness of 8.7 dtex), a relative viscosity (RV) of 3.0, and a strength of 2. It had properties of 36 cN / dtex, elongation of 52.5%, hot water shrinkage of 3.5%, and dry heat crimp of 12.8%.

[Manufacture of pile yarn]
Using two of the original polylactic acid crimped yarns obtained, the lower twist: Z180T / m, the upper twist: Z180T / m, to make a twisted yarn, and then twisted by hot air treatment at 115 ° C in the Sussen heat set equipment The pile yarn for tufted carpet was manufactured.

[Manufacture of backing layer]
Polyester needle punch nonwoven fabric (basis weight 400 g / ^{m 2} thickness 4 mm), latex 200 g / ^{m 2} coated with a roll coater, there is the waist, to produce a backing layer which is provided also cushioned.

[Manufacture of carpets]
A primary yarn for tufted carpet made of a polyester long-fiber nonwoven fabric, and a pile yarn of the above-mentioned original polylactic acid crimped yarn and an original polyester crimped yarn (fineness 1,300 dtex / 144 filament, two twists) Were alternately threaded and set in a 1/10 gauge, loop tufting machine to create a skin layer. A skin layer having a stitch (38/12 cm), a pile length (4 mm), and a basis weight (620 g / m ² ) was obtained.

Next, EVA pre-coating is applied to the back surface of the skin layer tufted with pile yarn, and 350 g / m ² of polyethylene resin powder having a particle size of 500 μm is applied to the bonding side of the skin layer 104 as shown in FIG. Then, it was heated at 160 ° C. for 1 minute, and the backing layer 105 was laminated thereon, cooled under pressure, and punched out to a 50 cm square to produce a tile carpet.

Table 1 shows the bulkiness of the carpets and the Taber abrasion test results.

<Example 2>
A tile carpet was produced in the same manner as in Example 1 except that the skin layer was obtained only with the pile yarn of the original polylactic acid crimped yarn. Table 1 shows the bulkiness of the carpet and the Taber abrasion test results.

<Example 3>
In Example 1, the production of the backing layer, although not latex coating, except that the polyester needle punch nonwoven fabric cushioned (basis weight 400 g / m ² thickness 4 mm) was backing layer as in Example 1 A tile carpet was manufactured. Table 1 shows the bulkiness of the carpet and the Taber abrasion test results.

<Comparative Example 1>
In Example 1, [Manufacture of original polylactic acid crimped yarn], the nozzle used 32 holes of Y cross section, and the obtained black original polylactic acid crimped yarn had a fineness of 1,105 dtex / 96 filaments (single The profile of the Y section of the yarn fineness of 11.5 dtex was 2.2. Relative viscosity (RV) is 3.0, strength is 1.67 cN / dtex, elongation is 32.2%, hot water shrinkage is 4.6%, dry heat crimp is 14.0%. In the same manner as in <Example 1>, a black original polylactic acid crimped yarn was produced and a tile carpet was produced. Table 1 shows the bulkiness of the carpet and the Taber abrasion test results.

<Comparative example 2>
In Example 1, a tile carpet was produced by laminating a vinyl chloride resin layer as a backing layer directly on the bonding surface of the skin layer. Table 1 shows the bulkiness of the carpet and the Taber abrasion test results.

It is a schematic sectional drawing of the tile carpet which shows one Example of this invention. It is explanatory drawing of the irregularity degree of a thread | yarn. It is a schematic block diagram which shows an example of the manufacturing apparatus used with the manufacturing method of the original polylactic acid crimped yarn. It is the schematic of the apparatus which shows an example which bonds a backing layer with a polyethylene resin powder.

Explanation of symbols

101: tile carpet 102a: pile yarn 102b: pile yarn 103: base fabric 105: backing layer 106: adhesive resin layer 107: spraying device 108: heating device
1: take-up roller 2: preheating roller 3: stretching roller 4: heat setting roller 5: heated fluid crimping device 10: polylactic acid resin inlet 11: additive inlet 12: twin screw extruder 14: spinning head 16: Spray cooling device 17: oiling device 20: cooling drum 21: entanglement processing device 22: cheese

Claims (2)

In a tile carpet comprising a skin layer comprising a pile yarn and a base fabric, an adhesive resin layer, and a backing layer, at least a piled original polylactic acid crimped yarn having a substantially circular or circular cross section of a single fiber as a pile yarn The original polylactic acid crimped yarn satisfies the following properties (1) to (7) simultaneously:
(1) The cross-sectional shape of the single fiber is substantially circular or circular, and the degree of profile expressed by the ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the fiber cross section Is less than 1.5
(2) Relative viscosity (RV) 2.5-3.8
(3) Strength 1.75 to 3.5 cN / dtex
(4) Elongation is 35-60%
(5) Single yarn fineness is 2.5-25 dtex
(6) Hot water shrinkage 2-8%
(7) Dry heat crimp rate is 5-25%
The adhesive resin layer is made of thermoplastic resin powder, and the backing layer is coated with 200 to 300 g / m ² (at the time of drying) of latex or resin emulsion from the lower surface side of the cushioning nonwoven fabric. Breathable tile carpet with improved vegetation, characterized by the remaining backing layer .   The tile carpet skin layer containing at least the original polylactic acid crimped yarn as a pile yarn has a wear amount of the pile yarn of 5 to 30 according to a Taber type wear test (wear wheel: H-18, number of wear 2,500 times). The air-permeable tile carpet with improved plant degree according to claim 1, wherein the air-permeable tile carpet has a weight percentage.