JP4804092B2 - carpet - Google Patents

Description

  The present invention relates to a carpet using an original polylactic acid crimped yarn made of a plant-derived raw material as a pile yarn, and in order to compensate for the disadvantages of the original polylactic acid crimped yarn, the raw material made of a petroleum-derived raw material having a proven track record. By using the synthetic fiber crimped yarn and the original polylactic acid crimped yarn at the same time as the pile yarn, it has excellent bulkiness, high toughness, excellent wear resistance, etc. The carpet is provided.

  In this specification, the term “original synthetic fiber crimped yarn” is used in a sense not including the original polylactic acid crimped yarn.

  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 suitable for the global environment and friendly to the environment. Vehicle option mats, household carpets, rugs, and the like using polylactic acid fibers made of such plant-derived materials have been made and put into practical use.

  However, conventional carpets using polylactic acid fibers have the disadvantages that they are inferior in bulkiness, are easy to wear and are easy to wear, and have been put to practical use only for limited applications. This is because the properties of the polylactic acid crimped yarn, such as strength and elongation, and its crimping properties are inferior to those of nylon, polypropylene and polyester fiber crimped yarns made from petroleum-derived materials. If the same physical properties as nylon, polypropylene, and polyester fiber crimped yarns can be obtained, it is expected that they can be widely used as materials for interiors as well as carpets.

  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 with a polylactic acid polymer and the backing material with a biodegradable material.

  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 a 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 above-mentioned problems and to reduce plantiness by using an original polylactic acid crimped yarn as a part (particularly a main part) of carpet pile yarn, which cannot be achieved by the prior art. It is to provide an improved carpet.

  The present invention provides the following means in order to solve the above problems.

  [1] A pile carpet constructed by using an original polylactic acid crimped yarn and an original synthetic fiber crimped yarn as a pile yarn, and a Taber type abrasion test (wear wheel: H-18, number of abrasions 5000 times) The carpet is characterized in that the abrasion amount of the pile yarn on the carpet skin is 5 to 30% by mass.

  [2] At least one original synthetic fiber crimp yarn selected from the group consisting of an original polyester crimp yarn, an original nylon crimp yarn and an original polypropylene crimp yarn as the original synthetic fiber crimp yarn. The carpet according to the preceding item 1, wherein: is used.

[3] The carpet according to item 1 or 2, wherein the original polylactic acid crimped yarn simultaneously satisfies the following characteristics (1) to (7):
(1) The cross-sectional shape of a single fiber is an approximate circle having a degree of deformity represented by the ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the cross section of the fiber. (2) Relative viscosity (RV) 2.5 to 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 to 25%.

[4] The carpet according to any one of items 1 to 3, wherein the carpet has an average pile length of 5 to 15 mm and a pile basis weight of 500 to 3500 g / m ² .

  [5] The carpet according to any one of items 1 to 4, wherein the original polylactic acid crimped yarn is made of a plant-derived raw material, and the original synthetic fiber crimped yarn is made of a petroleum-derived raw material.

  In the invention of [1], since the original polylactic acid crimped yarn and the original synthetic fiber crimped yarn are used as the pile yarn, the wear resistance is superior to the carpet using only the original polylactic acid crimped yarn. The carpet can be made into a carpet, and the wear amount of the pile yarn according to the Taber type abrasion test (wear wheel: H-18, number of abrasions 5000 times) of the carpet skin is 5 to 30% by mass. It can be. In addition, since it is an original yarn, there is no need to provide a dyeing step 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 excellent wear resistance. Can be a carpet.

  In the invention of [2], at least one original synthetic fiber crimp yarn selected from the group consisting of an original polyester crimp yarn, an original nylon crimp yarn and an original polypropylene crimp yarn, and an original polylactic acid Since both crimped yarns are used as pile yarns, there is no need to provide a dyeing step with heat treatment in the carpet manufacturing process, and the combustion heat is kept low at the time of incineration, so that it can be easily incinerated and discarded.

  In the invention of [3], 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, single yarn Since the fineness, hot water shrinkage and dry heat crimp rate are limited to specific ranges, they can be used as pile yarns together with the original synthetic fiber crimp yarns, which makes them even more bulky, tough and wear resistant. The carpet can be excellent in properties.

In the invention of [4], since the average pile length of the carpet skin is 5 to 15 mm and the pile basis weight is 500 to 3500 g / m ² , the carpet should be excellent in bulkiness and wear resistance and have no bottoming feeling. Can do.

  In the invention of [5], a carpet using a plant-derived raw material having high toughness and excellent wear resistance can be obtained.

  The present invention has been intensively studied on improvement of carpet abrasion resistance and lack of bulkiness, etc. using an original polylactic acid crimped yarn made of plant-derived materials as a pile yarn, and together with an original synthetic fiber crimped yarn The cross-sectional shape, relative viscosity (RV), strength, elongation, and single yarn fineness of the single fiber of the original polylactic acid crimped yarn used for the pile yarn by using the original polylactic acid crimped yarn as the pile yarn The fiber properties such as the hot water shrinkage rate and the dry heat crimp rate are limited to specific ones, and when the average pile length and pile basis weight of the carpet skin are specified, the above problems are all at once. We were able to provide a carpet to solve.

  The carpet of the present invention uses a pile yarn composed of an original polylactic acid crimped yarn and an original synthetic fiber crimped yarn, and is defined by a Taber type abrasion test (JIS L1096.88.17.3) for a carpet skin. The carpet is tested in accordance with the Taber type abrasion test, except that H-18 wear wheels are used and the number of wears is 5000. .

  Thus, when the abrasion amount of the pile yarn by the Taber type abrasion test of the carpet skin is 5 to 30% by mass, a carpet having excellent abrasion resistance can be obtained. Although it is most preferable if the wear amount of the pile yarn is less than 5% by mass, it is difficult to achieve in practical use. When the wear amount of the pile yarn exceeds 30% by mass, the fibers fall off over time while the carpet is used, and the carpet base fabric can be seen and the appearance is greatly changed.

  In the present invention, the method of using the original polylactic acid crimped yarn and the original synthetic fiber crimped yarn as the pile yarn is not particularly limited, and the pile yarn is combined as a pile yarn such as every other yarn or every other yarn. (See FIG. 1), and the composite polylactic acid crimped yarn (a) and the original synthetic fiber crimped yarn (b) are combined to form a composite yarn. (See FIG. 2).

  In the present invention, the method for producing the carpet is not particularly limited, and examples thereof include methods for producing 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 a cut pile, a loop pile, and a 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 inhibited, what copolymerized components other than lactic acid may be used. When a component other than lactic acid is copolymerized, it is 70% by weight or more and less than 100% by weight, preferably 80% by weight or more and less than 100% by weight, more preferably 90% by weight or more and 100% by weight, based on all repeating units of the polymer molecular chain. Less than the lactic acid unit.

  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 strength is considerably lower than the level, and the strength is not sufficiently improved. Among them, the relative viscosity of the original polylactic acid crimped yarn is preferably 2.8 to 3.6.

  Moreover, the polylactic acid composition used as a raw material for the original polylactic acid crimped yarn 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, the occurrence of thread breakage 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 carpet of the present invention using the original polylactic acid crimped yarn as a pile yarn is characterized in that the original polylactic acid crimped yarn used for the pile yarn satisfies the following characteristics (1) to (7) at the same time. And carpet.
(1) 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 preferably 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 (less than 1.5) ( (See FIG. 4). If 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 will tend to appear, and the wear resistance of the yarn will decrease. It is not preferable.
(2) The relative viscosity (RV) is 2.5 to 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 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 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 in the range of 500 to 3500 dtex. If it is such a range, it will become the optimal original crimped yarn for a tufted carpet use, However, It is not limited to the use for such a use in particular. Among these, the total fineness of the original polylactic acid crimped yarn is preferably in the range of 1000 to 3000 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 polylactic acid crimped yarn having a dry heat crimp rate of more than 25% is difficult to obtain with the current production technology, and even if it is obtained, the carpet constructed using the crimped yarn becomes felt-like, A preferred carpet is not 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 original synthetic fiber crimp yarn used in the present invention is preferably an original polyester crimp yarn, an original nylon crimp yarn or an original polypropylene crimp yarn. In consideration of environmental measures such as recyclability, the original polyester crimped yarn is most preferable. By using the original synthetic fiber crimped yarn made of petroleum-derived raw material and the original polylactic acid crimped yarn made of plant-derived raw material together with the pile yarn, only the original polylactic acid crimped yarn made of plant-derived raw material is used It is possible to further improve wear resistance, bulkiness, and the like as compared with the carpet.

  The pile yarn used for the carpet of the present invention is a non-twisted yarn and / or a twisted yarn of an original polylactic acid crimped yarn made of a plant-derived raw material and an original synthetic fiber crimped yarn made of a petroleum-derived raw material. It can be used as a yarn and / or two or more twisted yarns, or an original polylactic acid crimped yarn and an original synthetic fiber crimped yarn can be combined and used as a composite yarn (see FIG. 2).

Specifically, it is used as a pile yarn such as the following (1) to (7) using an original polylactic acid crimped yarn made of plant-derived materials and an original synthetic fiber crimped yarn made of petroleum-derived materials. be able to.
(1) Use untwisted yarn (raw yarn) as pile yarn (2) Use air yarn entangle the untwisted yarn and use pile yarn (3) Use twisted yarn as pile yarn (4) Twist number is 50 to 250 T / m Twisted yarn and used for pile yarn (5) Two or more twisted yarns used for pile yarn (6) Wet heat treatment or dry heat treatment of pile yarn (7) Original polylactic acid crimped yarn and original composition Combined fiber crimped yarn, heat set as composite yarn and used as pile yarn Appropriate selection of piled polylactic acid crimped yarn made of plant-derived raw material and raw synthetic fiber crimped yarn made of petroleum-derived raw material as pile yarn By using it, a carpet with improved wear resistance can be produced.

And the carpet of this invention uses the pile yarn of the original polylactic acid crimped yarn which consists of plant-derived raw materials, and the original synthetic fiber crimped yarn which consists of petroleum-derived raw materials, and the average pile length of carpet skin is 5-15 mm A structure having a pile basis weight of 500 to 3500 g / m ² is preferable.

  When an original polylactic acid crimped yarn made of a plant-derived raw material and an original synthetic fiber crimped yarn made of a petroleum-derived raw material are used as a pile yarn, the average pile length is 5 to 15 mm. Preferably, it is 6.5-15 mm. More preferably, it is 7.5-12 mm. Especially preferably, it is 8-12 mm. If the average pile length is less than 5 mm, the base fabric can be seen from the gaps in the pile skin, resulting in poor bulkiness and a feeling of bottoming when using the carpet. When the average pile length exceeds 15 mm, the bulkiness is excellent and there is a high-class feeling, but the cost is increased, and the pile yarn becomes weak and the pile becomes easy to sleep while using the carpet.

The pile basis weight is 500-3500 g / m ² . Preferably, it is 600-3200 g / m < ² >. More preferably, it is 800-3000 g / m < ² >. If the basis weight of the pile is less than 500 g / m ² , the base fabric can be seen through the gaps in the pile skin, resulting in poor bulkiness and a feeling of bottoming. When the pile basis weight exceeds 3500 g / m ² , the bulkiness is excellent and there is a high-class feeling, but it becomes heavy and handling of the carpet becomes difficult.

  For example, when a tufting machine is used to tuft the pile yarn of the original polylactic acid crimped yarn made of the plant-derived raw material and the original synthetic fiber crimped yarn made of the petroleum-derived raw material, the gauge is 1/16 to 1/4 (1 inch: 2.54 cm / number of stitches) is preferable. More preferably, it is 1/12 to 1/8. The stitches are 20 to 70 stitches / 10 cm, preferably 25 to 65 stitches / 10 cm. More preferably, 35 to 60 stitches / 10 cm is preferable, and 40 to 60 stitches / 10 cm is most preferable.

  The carpet using the original polylactic acid crimped yarn made of the plant-derived raw material and the original synthetic fiber crimped yarn made of the petroleum-derived raw material as a pile yarn is subjected to a backing treatment to fix the pile yarn after tufting. The At this time, it passes through a drying step and a heat setting step, and usually by dry heat treatment and / or steam treatment, the original polylactic acid crimped yarn made of the plant-derived raw material and the original synthetic fiber yarn made of the petroleum-derived raw material A crimp that is latent in the crimped yarn is expressed, and the carpet is excellent in bulkiness and has no bottoming feeling.

  The tufted carpet using the above-identified original polylactic acid crimped yarn made of the plant-derived material of the present invention and the original synthetic fiber crimped yarn made of the petroleum-derived material as a pile yarn has excellent bulkiness and volume feeling. A good carpet. Further, a carpet having greatly improved wear resistance and settling resistance can be obtained.

  The carpet using the original polylactic acid crimped yarn made of a plant-derived raw material and the original synthetic fiber crimped yarn made of a petroleum-derived raw material as a pile yarn of the present invention includes a roll carpet, a piece carpet, a tile carpet, an automobile carpet and These are optional mats, household rugs and mats, etc., and can be used for many purposes by utilizing the characteristics of the carpet of the present invention.

  In the carpet of the present invention, the original polylactic acid crimped yarn is used as a part (especially the main part) of the pile yarn. If a lactic acid resin is contained, the degree of vegetation is further improved, and it is possible to obtain a carpet that is friendly to the global environment from the viewpoint of environmental protection, with little increase in carbon dioxide in the air.

  Next, although the specific manufacturing method of the original polylactic acid crimped yarn required for this invention is described, it is not limited to this manufacturing method (refer FIG. 3).

  The polylactic acid polymer used for the production of the original polylactic acid crimped yarn has a relative viscosity (RV) measured from a mixed solution of 20 ° C. and phenol / tetrachloroethane = 60/40 (mass ratio) of 2.5 to Use 3.8. In the carpet application of the present invention, the strength and elongation of the crimped yarn, the crimp characteristics and the abrasion resistance are required, and therefore a high molecular weight polylactic acid polymer, that is, a polymer having the above-mentioned relative viscosity is required.

  As the inorganic pigment and the organic pigment used as the colorant of the original polylactic acid crimped yarn, at least one pigment selected from the above-mentioned specified compounds is used. Alternatively, the colorant can be added to the polylactic acid polymer to form a master batch, and then the yarn can be produced.

  The polylactic acid polymer in which the polylactic acid polymer and the colorant are mixed at a constant ratio via a mixer is supplied to a vented (13) twin screw extruder (12) to be melted, and through a spinning pack, Spin from 15).

  The cross section of the original polylactic acid crimped yarn has a substantially circular or circular shape, and the ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the single yarn cross section. Is preferably less than 1.5.

  Next, the spun yarn is cooled and solidified by the cold air of the spray cooling device (16).

  An oil agent is applied to the cooled and solidified yarn by an oiling device (17), and then wound by a take-up roller (1) that rotates at a predetermined speed.

  The speed of the take-up roller (1) is 400 to 1000 m / min.

  The method for producing a crimped yarn according to the present invention is characterized by a direct spinning drawing / crimping process in which the crimped yarn is produced in one step. Therefore, the take-up speed is preferable.

  The undrawn yarn filament taken up is continuously heat-drawn in a single stage or multiple stages of two or more stages using a roller group (1 to 4). The temperature of the stretching roller (3) is 70 to 125 ° C. The draw ratio is in the range of 3.0 to 6.0. In particular, in order to obtain the high strength, elongation and high crimp characteristics of the original polylactic acid crimped yarn of the present invention and excellent bulkiness and wear resistance when used as a carpet, It is important to crimp the lactic acid fiber.

  A sufficiently stretched and oriented polylactic acid fiber is heat set by a heat setting roller (4). The temperature of the heat setting roller (4) is 100 to 150 ° C. By optimizing the temperature range of the heat setting roller (4), the crystallization of the polylactic acid fiber is controlled, and the desired physical properties are obtained.

  The polylactic acid fiber yarn that has been stretched is continuously introduced into the heated fluid crimping device (5) to impart crimps. The yarn (6) crimped by the heated fluid crimp imparting device (5) is cooled on the cooling drum (20).

  The heating fluid is preferably heated air, and its use temperature is 90 to 160 ° C. Appropriate conditions are selected according to the fineness of polylactic acid fiber, processing speed, and the like.

  Next, the crimped yarn is entangled through the nozzle of the entanglement processing device (21). The entanglement nozzle usually has 2 to 6 holes, and entanglement treatment is performed by injecting high pressure air of 0.2 to 0.5 MPa from a direction substantially perpendicular to the traveling crimped yarn.

  Next, the polylactic acid crimped yarn is wound into a cheese shape (22). The winding tension is performed at a low tension of 0.10 cN / dtex or less.

  Next, the manufacturing method of the pile yarn used for the carpet of this invention is described. The pile yarn used for the carpet of the present invention is made of the above-mentioned original polylactic acid crimped yarn made from plant-derived materials and original synthetic fiber crimped yarn made from petroleum-derived materials (hereinafter referred to as both crimped yarns). They can be used in the state of twisted yarn and / or twisted yarn, or as a single yarn and / or two or more twisted yarns. Also, both crimped yarns can be combined and heat-set as a composite yarn and used as a pile yarn.

  The pile yarn using the both crimped yarns is based on the production standard of tufted carpet, and the color of the pile yarn, the total fineness (dtex), the state of the both crimped yarns (no twisted yarn or twisted yarn), Determine the number of combined yarns and the condition and form of the twisted yarn.

  Both crimped yarns may be used in the state of untwisted yarn, or the untwisted yarn and other untwisted yarns may be used as they are / or twisted as mixed fiber in an air entanglement facility.

  Moreover, both crimped yarns may be used in the state of twisted yarn (twisting number is preferably 150 to 250 T / m), and twisted into two or more after twisting (twisting number is preferably 50 to 200 T / m). It can also be used.

  For example, two or three original polylactic acid crimped yarns are used and subjected to a lower twist (180 T / m) and an upper twist (180 T / m) to obtain a twisted crimped yarn. After that, twist setting is performed by hot air treatment at 100 to 125 ° C. or vacuum steam heat treatment at 90 to 115 ° C. to obtain pile yarn for carpet.

  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 (mass 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. Invisible (◎), difficult to see (○), somewhat visible (△), well visible (×).

[Abrasion resistance]
Carpet wear resistance is evaluated in accordance with the Taber type wear test (JIS L 10968.8.17.3 (2004 edition)). And the number of wear was set to 5000 times). That is, using an H-18 wear wheel, a load of 9.8 N is applied to each wear wheel, the test stand is rotated 5000 times to wear the test piece, and the wear amount of the pile yarn is measured. The Taber wear amount (% by mass) is obtained from the following formula.
Taber wear amount (mass%) = pile drop-off mass of wear ring part after test / pile part mass of wear ring part before test x 100%

  Hereinafter, the present invention will be described in detail using examples.

<Examples 1-1 to 1-4>
[Production of original polylactic acid crimped yarn made from plant-derived materials]
An original polylactic acid crimped yarn was produced using a production apparatus having the structure shown in FIG. From a polylactic acid resin inlet (10), a polylactic acid chip (polymer of lactic acid monomers comprising 98% by mass of L-lactic acid and 2% by mass of D-lactic acid. Mass average molecular weight: 140,000, relative viscosity: 3.2, melting point: Tm = 170 ° C.) While 100 parts by mass were charged, 4 parts by mass of a 25% by mass carbon black masterbatch made of the same polylactic acid resin was introduced from the additive inlet (11), and the twin screw extruder (12). It melt-kneaded at 230 degreeC, carrying out deaeration. The content of carbon black as a colorant was 1.0% by mass.

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

  The spun yarn was cooled and solidified with cold air (20 ° C. × 70%) of a 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% by weight water emulsion type oil agent for polylactic acid yarn is applied by an oiling device (17) to a non-heated take-up roller (1) that rotates at a speed of 423 m / min. I wound up and picked it up. Then, the yarn was pre-heated by winding with a preheating roller (2) continuously heated to 70 ° C. at a speed of 426 m / min and wound on a drawing roller (3) at a speed of 444 m / min heated to 105 ° C. Then, it extended | stretched between the heat set rollers (4) heated to 123 degreeC rotated at a speed | rate of about 2000 m / min. The draw ratio was 4.5 times.

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

  The obtained black original polylactic acid crimped yarn has a circular cross section (round cross section) having a total fineness of 1673 dtex / 192 filament (single yarn fineness of 8.7 dtex), a relative viscosity (RV) of 3.0, and a strength of 2.36 cN. / dtex, the elongation was 52.5%, the hot water shrinkage was 3.5%, and the dry heat crimp was 12.8%.

[Original synthetic fiber crimped yarn derived from petroleum]
An original polyester crimped yarn was used as an original synthetic fiber crimped yarn of a petroleum-derived raw material. The black original polyester crimped yarn has a trilobal cross section with a fineness of 1471 dtex / 96 filament (single yarn fineness of 15.3 dtex), a strength of 3.22 cN / dtex, an elongation of 35.1%, and a hot water shrinkage of 3. It had a physical property of 5% and a dry heat crimp rate of 23.7%.

[Manufacture of pile yarn made of plant-derived materials]
Using the obtained black original polylactic acid crimped yarn made of plant-derived raw material, applying a lower twist: Z180 T / m, an upper twist: Z180 T / m to form a two-ply twisted yarn, and 115 using a Sussen heat setting facility Pile yarn made of plant-derived raw material for tufted carpet was manufactured by twisting with hot air treatment at 0 ° C.

[Manufacture of pile yarn made of petroleum-derived raw materials]
Two black crimped polyester crimped yarns made from the above-mentioned petroleum-derived raw materials are used, and after twisting: Z180T / m and top twisting: Z180T / m to make a twisted yarn, hot air treatment at 180 ° C. is carried out at the Sussen heat set equipment The pile yarn which consists of the petroleum-derived raw material for tufted carpets was manufactured.

[Manufacture of carpets]
Using a tufting machine, one of the above-mentioned two types of pile yarns is alternately placed on a primary base fabric for tufted carpet made of polyester non-woven fabric, gauge (1 inch: 2.54 cm / 10 stitches), stitch ( The number of piles / 10 cm), the average pile length (mm), and the pile weight per unit area (g / m ² ) were changed, and tufted piles of Examples 1-1 to 1-4 in Table 1 according to the respective standards. Created an original fabric.

  Next, the back surface of the tufted pile original fabric tufted with pile yarn was pre-coated with SBR latex, and a tufted carpet was produced using a polyethylene resin sheet as a backing agent.

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

<Examples 2-1 to 2-5>
[Production of original polylactic acid crimped yarn made from plant-derived materials]
A black original polylactic acid crimped yarn made of a plant-derived raw material was produced in the same manner as in Example, except that the nozzle had 32 holes with a Y cross section.

  The obtained black-lacquered polylactic acid crimped yarn made of plant-derived materials had a trilobal cross section with a fineness of 1105 dtex / 96 filament (single yarn fineness of 11.5 dtex) and a degree of deformity of 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%. Was.

[Manufacture of pile yarn made of plant-derived materials]
After using three black-colored polylactic acid crimped yarns made of the above plant-derived raw materials and applying a lower twist: Z180 T / m, an upper twist: Z180 T / m to make a twisted yarn, hot air at 115 ° C. is used in a Sussen heat setting facility Pile yarn made of plant-derived raw material for tufted carpet was manufactured by twisting treatment.

[Manufacture of pile yarn made of petroleum-derived raw materials]
Two black crimped polyester crimped yarns made from the above-mentioned petroleum-derived raw materials are used, and after twisting: Z180T / m and top twisting: Z180T / m to make a twisted yarn, hot air treatment at 180 ° C. is carried out at the Sussen heat set equipment The pile yarn which consists of the petroleum-derived raw material for tufted carpets was manufactured.

[Manufacture of carpets]
Using a tufting machine, a tufted carpet base fabric made of polyester long-fiber non-woven fabric, alternately with the above two types of pile yarn, gauge (1 inch: 2.54 cm / 10 stitches), stitch (stitch) Number / 10 cm), the average pile length (mm), and the weight per unit area (g / m ² ) of the pile portion were changed, and the tufted pile raw materials of Examples 2-1 to 2-5 in Table 2 in each standard Created anti.

  In the same manner as in Examples 1-1 to 1-4, the back side of the tufted pile original fabric was precoated with SBR latex, and tufted carpets were produced using a polyethylene resin sheet as a backing agent.

  Table 2 shows the bulkiness and Taber abrasion test results of the carpets of <Examples 2-1 to 2-5>.

<Comparative Examples 1-1 to 1-8>
Manufacture of carpets made of 100% pile yarn made from plant-derived materials (1)
[Original polylactic acid crimped yarn made from plant-derived materials]
The same original polylactic acid crimped yarn as in Examples 1-1 to 1-4 was used. The obtained black original polylactic acid crimped yarn has a circular cross section (round cross section) having a total fineness of 1673 dtex / 192 filament (single yarn fineness of 8.7 dtex), a relative viscosity (RV) of 3.0, and a strength of 2.36 cN. / dtex, the elongation was 52.5%, the hot water shrinkage was 3.5%, and the dry heat crimp was 12.8%.

[Pile yarn made of plant-derived materials]
The same original polylactic acid crimped yarn as in Examples 1-1 to 1-4 was used. That is, using a black original polylactic acid crimped yarn made of a plant-derived raw material, applying a lower twist: Z180 T / m, an upper twist: Z180 T / m to form a two-ply twisted yarn, 115 ° C. in a Sussen heat setting facility The pile yarn was made from plant-derived materials for tufted carpets.

[Manufacture of carpets]
As in <Examples 1-1 to 1-4>, using a tufting machine, all the pile yarns of the above-mentioned original polylactic acid crimped yarn were applied to a primary base fabric for tufted carpet made of a polyester long-fiber nonwoven fabric. Change the conditions of gauge (1 inch: 2.54 cm / 10 stitches), stitch (number of stitches / 10 cm), average pile length (mm), pile area weight (g / m ² ) The tufted pile original fabric of Comparative Examples 1-1 to 1-8 in Table 3 was prepared for each standard.

  As in <Examples 1-1 to 1-4>, a tufted pile carpet is manufactured by pre-coating with SBR latex on the back side of a tufted pile original fabric tufted with pile yarn, and using a polyethylene resin sheet as a backing agent. did.

  The standards, bulkiness and Taber abrasion test results of these carpets are shown in Table 3 as <Comparative Examples 1-1 to 1-8>.

<Comparative Examples 2-1 to 2-5>
Manufacture of carpets made of 100% pile yarn made from plant-derived materials (2)
[Original polylactic acid crimped yarn made from plant-derived materials]
The same original polylactic acid crimped yarn as in Examples 2-1 to 2-5 was used. The obtained black-lacquered polylactic acid crimped yarn made of plant-derived materials had a trilobal cross section with a fineness of 1105 dtex / 96 filament (single yarn fineness of 11.5 dtex) and a degree of deformity of 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%. Was.

  Hereinafter, in the same manner as in <Examples 2-1 to 2-5>, [pile yarn made of plant-derived materials] and [manufacturing carpet] are performed, and the carpet specifications, bulkiness, and Taber abrasion test results are obtained. Is shown in Table 4 as <Comparative Examples 2-1 to 2-5>.

It is the schematic which shows an example of the carpet of this invention. It is the schematic which shows an example of the carpet of this invention. 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 explanatory drawing of the irregularity degree of a thread | yarn.

Explanation of symbols

A: Pile yarn row made of plant-derived raw material B: Pile yarn row made of petroleum-derived raw material a: Original polylactic acid crimped yarn made of plant-derived raw material b: Original synthetic fiber crimped yarn made of petroleum-derived raw material c: Base fabric 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: Entangling device 22: Cheese

Claims (5)

A pile carpet constructed by using an original polylactic acid multifilament crimped yarn and an original synthetic fiber crimped yarn as a pile yarn,
The original polylactic acid multifilament crimped yarn simultaneously satisfies the following properties (1) to (7):
(1) The cross-sectional shape of the single fiber is substantially circular or circular (2) Relative viscosity (RV) 2.5 to 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 8-20%
A carpet characterized in that the amount of wear of the pile yarn on the carpet skin is 5 to 30% by mass according to a Taber type abrasion test (wear wheel: H-18, number of wear 5000 times).   As the original synthetic fiber crimp yarn, at least one original synthetic fiber crimp yarn selected from the group consisting of an original polyester crimp yarn, an original nylon crimp yarn and an original polypropylene crimp yarn is used. The carpet according to claim 1. Carpet according to claim 1 or 2 mean pile length of the carpet epidermis 6.5～15Mm, pile weight per unit area is characterized by a 600~3200g / m ^2. Degree of profile represented by the ratio (B / A) of the diameter (B) of the circumscribed circle to the diameter (A) of the inscribed circle of the single fiber of the original polylactic acid multifilament crimped yarn The carpet according to any one of claims 1 to 3, which has a substantially circular shape or a circular shape having a diameter of less than 1.5 .   The carpet according to any one of claims 1 to 3, wherein a cross-sectional shape of a single fiber of the original polylactic acid multifilament crimped yarn is circular.

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