EP1130149A1 - Grundgewebe für tufting-teppich sowie zugehörender tufting-teppich - Google Patents

Grundgewebe für tufting-teppich sowie zugehörender tufting-teppich Download PDF

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Publication number
EP1130149A1
EP1130149A1 EP00919168A EP00919168A EP1130149A1 EP 1130149 A1 EP1130149 A1 EP 1130149A1 EP 00919168 A EP00919168 A EP 00919168A EP 00919168 A EP00919168 A EP 00919168A EP 1130149 A1 EP1130149 A1 EP 1130149A1
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EP
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Prior art keywords
base cloth
filament
nonwoven fabric
filaments
tufted carpet
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EP00919168A
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English (en)
French (fr)
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EP1130149A4 (de
EP1130149B1 (de
Inventor
Atsushi Unitika Ltd MATSUNAGA
Tomoko Unitika Ltd WATANABE
Mamiko Unitika Ltd MATSUNAGA
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Unitika Ltd
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Unitika Ltd
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Publication of EP1130149A4 publication Critical patent/EP1130149A4/de
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    • 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
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • 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
    • D01F6/625—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters derived from hydroxy-carboxylic acids, e.g. lactones
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • 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
    • 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
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • 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
    • D06N2209/1607—Degradability
    • D06N2209/1614—Biodegradable
    • 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
    • D06N2209/1628—Dimensional stability

Definitions

  • the present invention relates to a base cloth for tufted carpet comprised of nonwoven fabric made of accumulated filaments and the carpet using the same.
  • Nonwoven fabric made of a large number of accumulated filaments is used for base cloth for tufted carpet.
  • Known base cloth for tufted carpet is used as a supporting and backing medium wherein pile yarn is embedded and tufted.
  • the base cloth is mainly made of nonwoven fabric of polyethylene-terephthalate.
  • the tufted carpet makes a bulky waste and is difficult to be disposed. Because the heat quantity generated in connection with the incineration is large when the carpet is to be disposed by incineration, the service life of the incinerator may be shortened and toxic gas or black smoke may be generated. And when the carpet is disposed by landfilling method there may occur a detrimental effect on environment because of its non-biodegradable nature. When polyvinyl chloride is used as backing layers for the carpet, dioxin may be generated when the backing layers are incinerated.
  • pile yarn is implanted onto the base cloth, and backing layers are used in the side opposite to the pile side of this base cloth in order to prevent loss of pile yarn.
  • backing layers are covered with second base cloth. Because these materials are not made of the same raw materials, the carpet is difficult to be recycled.
  • the base cloth for the tufted carpet according to the present invention is constituted by nonwoven fabric made of filament of poly lactic acid based polymer.
  • the filament has a round cross-section, birefringence of 12 ⁇ 10 -3 to 30 ⁇ 10 -3 and crystallization degree of 15 to 25 percent by weight.
  • the base cloth for the above described tufted carpet has heat shrinkage of less than 1 percent at 120 °C in three minutes in both directions of machine direction (MD) and cross direction (CD).
  • the base cloth for the tufted carpet according to the present invention is constituted by nonwoven fabric made of filament of poly lactic acid based polymer.
  • the above described filament has a non-round cross-section and crystallization degree of 15 to 25 percent by weight.
  • the above described base cloth for the tufted carpet has heat shrinkage of less than 1 percent at 120 °C in three minutes in both direction of MD and CD.
  • the tufted carpet according to the present invention includes the above described base cloth.
  • the carpet preferably has a configuration wherein the pile yarn made of poly lactic acid based polymer is tufted on the base cloth.
  • Preferably backing layers made of biodegradable material is provided in the side opposite to the tufted pile side of this base cloth.
  • the base cloth used for the tufted carpet is constituted by a nonwoven fabric made of filament of poly lactic acid based polymer
  • the base cloth has required biodegradability, and, as a result, does not cause environmental problems in nature.
  • Poly lactic acid apparently, due to its chemical structure, has higher stiffness than polyester.
  • the filament easily slips off a needle. Therefore a damage given to fiber decreases, and mechanical strength of the tufted base cloth is maintained.
  • the final product is for example a tile carpet, it maintains stiffness, and may have an improvement in workability during the installation on the floor.
  • the base cloth of the present invention is superior in thermal stability. Therefore the base cloth has durability to heat, without shrinking, given in the process where it is laminated or coated by the backing layer during the backing process and where it is heated in the oven during backing layer hardening process after the layer is attached. As a result, a carpet with excellent dimensional stability is provided.
  • the base cloth for the tufted carpet of the present invention is constituted by nonwoven fabric made of filament formed by poly lactic acid based polymer.
  • the poly lactic acid based polymer is superior in biodegradability and spinnability compared with other polymers. In addition, it has higher stiffness compared with polyester or other filament as is apparent considering the chemical structure of poly lactic acid.
  • this base cloth is tufted it is difficult that tufting needle directly sticks filaments of the base cloth and as a result, the filament can slip off the needle. Therefore the damage on the filament decreases, and mechanical strength of the tufted base cloth is maintained.
  • the tile carpet with enough stiffness shows an improved workability when it is laid on the floor.
  • poly lactic acid based polymer the polymer with melting point of equal to or higher than 100 °C selected from the following group is preferably used.
  • the group includes poly (D-lactic acid), poly (L-lactic acid), copolymer of D-lactic acid and L-lactic acid, copolymer of D-lactic acid and hydroxycarboxylic acid, copolymer of L-lactic acid and hydroxycarboxylic acid, copolymer of D-lactic acid, L-lactic acid and hydroxycarboxylic acid.
  • a blend of the polymers with melting point equal to or higher than 100 °C is also preferable.
  • Poly (L-lactic acid) and poly (D-lactic acid) which are homopolymer of poly lactic acid have melting point of about 180 °C.
  • the copolymerizing ratio of monomers is determined to give the melting point of the resulting copolymer of higher than 120 °C. It is desirable for this purpose that the copolymerization mole ratio of (D-lactic acid) /(L-lactic acid) is in the range of 100/0 to 90/10 or 10/90 to 0/100.
  • hydroxycarboxylic acid in the case of copolymer of lactic acid and hydroxycarboxylic acid, the hydroxycarboxylic acid selected from the group of glycolic acid, hydroxy butyric acid, hydroxy valeric acid, hydroxy pentanic acid, hydroxy caproic acid, hydroxy heptanic acid and hydroxy octanoic acid are used. It is particularly preferable to use hydroxy caproic acid or glycolic acid in terms of cost.
  • the filament obtained from the poly lactic acid based polymer when it has round cross-section, necessarily has birefringence of 12 ⁇ 10 -3 to 30 ⁇ 10 -3 and crystallization degree of 15 to 25 percent by weight.
  • “Round” here means that cross-section is round enough where birefringence of the fiber can be measured.
  • Birefringence represents the degree of molecular orientation. If the birefringence is lower than 12 ⁇ 10 -3 and the crystallization degree is lower than 15 percent by weight, residual elongation of this filament increases because of insufficient molecular orientation and excessively low crystalinity of the poly lactic acid consisting the filament. As a result, the provided nonwoven fabric namely base cloth shows a tendency of having insufficient dimensional stability and mechanical property. In addition, because the base cloth has poor heat stability, it cannot have durability to heat given during the backing process in the after-mentioned carpet manufacturing process, causing the base cloth shrinking, and as a result, the carpet with excellent dimensional stability cannot be obtained. Therefore the base cloth without above described properties is not suitable for the base cloth of the tufted carpet.
  • the dimensional stability and the mechanical property of the nonwoven fabric become excellent, but the stiffness of the filament becomes too high resulting in poor flexibility. Therefore, the filament receives heavier damage by the tufting needle during the tufting process and the tensile strength of the base cloth after tufting decreases.
  • the tufted carpet is necessarily processed by thermal molding for example, it gives poor moldability.
  • birefringence is measured using polarizing microscope with Berek compensator and tricresylphosphate as immersion liquid.
  • the crystallization degree is measured by the following methods.
  • the filament for measuring is ground into powder and packed into an Aluminium sampling case (20 ⁇ 18 ⁇ 0.5 mm), thereby a target sample is formed.
  • the vertically held sample is irradiated by Cu-K ⁇ -ray from a direction perpendicular to the sample using RAD-rB type of X-ray generator by Rigaku Corporation.
  • the base cloth of the present invention has heat shrinkage of less than 1 percent.
  • the heat shrinkage here is the one in both MD and CD, and is measured at 120 °C for three minutes. The reason is described below. Tufted carpet is manufactured, as is described later, by tufting pile yarn to the base cloth and by attaching backing layer to fix the pile yarn. When the backing layer is attached, a backing material heated and melted is usually extruded and laminated to the base cloth. After the lamination process the laminated carpet is introduced into oven to dry and harden the material. If the heat shrinkage is more than 1 percent, the base cloth cannot have durability to heat given in the backing process, giving shrinking to the base cloth, and as a result, a carpet with excellent dimensional stability cannot be obtained. In the case that the carpet is treated in the after-dyeing process the carpet is treated with steam under temperature over 100 °C, and then the base cloth shrinks resulting in the carpet with poor dimensional stability.
  • the structure of the filament in the nonwoven fabric providing the base cloth of the present invention may be in the form of monocomponent structure comprised of poly lactic acid based homopolymer or may be in the form of multicomponent structure comprised of plurality of polymers.
  • a sheath-core type, side-by-side type, island-sea type or multilobed type structure may be preferable.
  • sheath-core, side-by-side or island-sea both cases of round and non-round cross-sections are possible.
  • multilobed type only the non-round cross-section is possible.
  • the filament of the monocomponent structure does not contain polymer with low melting point giving binder material, it can provide base cloth with low heat shrinkage.
  • the filament of multicomponent structure is obtained from a combination of polymer with low melting point and polymer with high melting point.
  • the polymer with high melting point preferably has melting point of 20 °C higher than the one of the polymer with low melting point. And a portion of the polymer with low melting point is preferably located on the surface of the filament.
  • the polymer with low melting point is softened or melted in the step of heat treatment to manufacture the nonwoven fabric, giving thermal bonding between the filaments.
  • the polymer with high melting point maintains its filament structure without receiving any effect by heating.
  • the nonwoven fabric made of the filament maintains mechanical property such as dimensional stability, tensile strength and superior flexibility.
  • the friction resistance of needle penetrating the thermal bonding area decreases and as a result, easy tufting motion of needle is obtained.
  • the ratio of the polymer with high melting point is less than 10 percent, the portion of the polymer with low melting point in the area bonded with heat and pressure becomes excessive, and as a result, the mobility of the filament is limited by harder bonding between the filaments. Then it becomes difficult for the filament to follow needle motion and the filament is broken. And then in some case the base cloth may not obtain the property requested as the base cloth for carpet because of inferior mechanical strength.
  • the ratio of the polymer with high melting point is more than 90 percent, it means the portion of the polymer with low melting point is insufficient, and the thermal bonding forming the nonwoven fabric cannot be enough. Therefore, the provided mechanical property of the nonwoven fabric decreases and the advantage using the polymer with low melting point is not performed. For this reason, the ratio of (polymer with high melting point)/(polymer with low melting point) is more preferably 70/30 to 30/70 by weight.
  • the polymer with low melting point it is preferable for the polymer with low melting point to have compatibility with the polymer with high melting point.
  • a combination between copolymers of different mol ratio of D-lactic acid and L-lactic acid and a combination between poly lactic acid as polymer with high melting point and copolymer of lactic acid and hydroxycarboxylic acid as polymer with low melting point are preferable.
  • the above described poly lactic acid based polymer may contain any additives such as flatting agent, pigment, flame repellent, antifoaming agent, antistatic agent, antioxidant and UV absorbant, so far as the object of the present invention is not damaged.
  • the sheath-core type multicomponent structure When the sheath-core type multicomponent structure is used, the polymer with high melting point is located in the core, and the polymer with low melting point which makes the binder element to manufacture the nonwoven fabric by thermal processing is located in the sheath.
  • this sheath-core structure When this sheath-core structure is adopted, only the sheath component will be soften or melted, bonding the filaments each other during the thermal bonding process for manufacturing the nonwoven fabric. In this case, the core maintains a form of filament. Therefore, even if the tufting needle touches the bonding between the sheath filaments and breaks the bonding during the tufting process, the strength of the base cloth will decrease only a little.
  • the sheath in the surface of the filament is damaged but the core, in the inside of the filament, is not damaged.
  • the filament with multicomponent structure is less damaged than the filament with monocomponent structure and as a result, the decrease in strength of the base cloth is smaller.
  • Multilobed type filament with multicomponent structure will be described in detail in the following paragraph.
  • This multilobed type filament has a cross-section of a multilobed shape where the polymer with high melting point is located in the core and the polymer with low melting point is located in more than 2 lobe parts. More than 2 lobe parts form a plurality of projecting part on the surface of the filament.
  • the polymer with low melting point, as bonding element has wider surface area because of the above described construction. Therefore, the nonwoven fabric can have larger number of bonded area between the filaments of the nonwoven fabric. Accordingly when the nonwoven fabric is manufactured by bonding with heat and pressure, enough bonding strength can be obtained without processed under excessive pressure. As a result, the base cloth with high tensile strength and elongation can be obtained.
  • the polymer with low melting point projects on the surface of the filament, the polymer softened or melted can flow into the void between the filaments during the bonding with heat and pressure. As a result, the void is filled with the polymer.
  • increase of the strength of the nonwoven fabric is obtained not only in length and width direction but in thickness direction.
  • the degree of the projection or the shape of the lobe part (projecting part) constituted by the polymer with low melting point can be changed by selecting the weight ratio of (polymer with high melting point)/(polymer with low melting point) or the ratio of melt flow viscosity between the component polymers.
  • the number of the lobe part of the multilobed type conjugate filament is more than 2 and preferably 3 to 10 and more preferably 3 to 6. If the number of the lobe part is excessive, the degree of projection of the lobe part (the projecting part) becomes small and as a result, the lobe part cannot exert its effectiveness.
  • FIG. 1 is a schematic view showing a cross-section of an example of multilobed type filament constituting the base cloth of the present invention.
  • This multicomponent filament 1 has the polymer with high melting point 2 in its core and has two or more lobe parts having the polymer with low melting point 3.
  • the polymer with high melting point 2 and the polymer with low melting point 3 each appear on the surface of the filament 1 in turn.
  • the construction can be performed, wherein the polymer with high melting point 2, which is considerably higher melting point than temperature of bonding with heat and pressure, partially appears on the surface of the filament 1.
  • the advantage is obtained, wherein even if the temperature in the bonding with heat and pressure is raised up to about the melting point of the polymer with low melting point 3, the surface of the thermal pressing roll is not covered with softened or melted polymer.
  • FIG. 2 is a schematic view showing a cross-section of other example of multilobed type conjugate filament constituting the base cloth of the present invention.
  • the projecting lobe part is formed in the shape where all the polymer with high melting point 2 is surrounded by the polymer with low melting point 3.
  • Nonwoven fabric using filament is manufactured by the known method, for example, spunbond process.
  • filament is taken up according to melt spinning method and the filament is then accumulated by being piled up onto moving accumulating conveyer.
  • the poly lactic acid based polymer is melt spun from standard spinning nozzle. After the filament spun is cooled, it is drawn and attenuated using an air sucker. After the filament is opened by known method, it is accumulated as web on the moving accumulating device.
  • the take up speed in drawing by an air sucker is preferably, for example, 3000 to 6000 m/minute.
  • the molecular orientation of the poly lactic acid forming filament is not obtained enough, therefore the tensile strength of the filament becomes inferior. And as a result, the mechanical strength of the nonwoven fabric using the filament becomes poor.
  • the spinnability in melt spinning will be inferior. If the filament is obtained which does not have enough orientation of the poly lactic acid (undrawn filament) by the speed of less than 3000 m/minute, the filament may be drawn or drawn and heated after spinning. Thus, the filament of poly lactic acid (undrawn) may be oriented enough and as a result, the nonwoven fabric with birefringence and crystallization degree according to the present invention is obtained.
  • the example of the filament nonwoven fabric is selected from a group of the followings, that is, the filament nonwoven fabric of monocomponent structure, the nonwoven fabric of multicomponent structure, the nonwoven fabric blends of monocomponent filament and multicomponent filament, and the nonwoven fabric blends of the monocomponent filament and the monocomponent filament consisting of different polymer from that of the other.
  • Fineness of filament constituting the nonwoven fabric is preferably 2 to 14 dtex. If the fineness is less than 2 dtex, the tensile strength of the nonwoven fabric becomes low. When this nonwoven fabric needs to be processed by needle punching or by pile tufting, the filaments may easily be cut, and even if it is blended with coarser fineness filament, the tufted carpet obtained has a tendency to have inferior strength.
  • filament of more than 14 dtex the number of filaments constituting the nonwoven fabric decreases in unit weight. This means less number of bonded area between the filaments and sometimes gives inferior mechanical property of the nonwoven fabric obtained. In some cases, the bonded area between the filaments in the nonwoven fabric is easily broken. Therefore, the whole nonwoven fabric becomes rough and the flexibility of the carpet obtained may be damaged. As a result, the properties requested cannot be obtained.
  • the apparent density of the base cloth of the present invention is preferably equal to or less than 0.4 g/cm 3 .
  • the minimum of the apparent density is preferably about 0.08 g/cm 3 considering the weight and thickness of the base cloth.
  • the apparent density is more preferably 0.1 to 0.35 g/cm 3 .
  • the base cloth of the present invention is preferably needle-punched nonwoven fabric where the filaments are entangled with each other by needle punching.
  • the filaments constituting nonwoven fabric are entangled with each other not only two-dimensionally but in thickness direction, the peeling between layers in the base cloth will not occur during the tufting process and as a result, dimensional stability is sufficiently kept.
  • the preferable needle punching density is generally 20 to 100 punches/cm 2 . If the density is less than 20 punches/cm 2 , the filaments are insufficiently entangled with each other and needle punching effect is not obtained. On the other hand, if the density exceeds 100 punches/cm 2 , the degree of entangle between the filaments becomes stronger but the filaments are deeply damaged by the needle. As a result, the tensile strength of the filaments intensely decreases, giving poor mechanical strength of the base cloth.
  • Some bonded part, in which the filaments are thermally bonded with each other, is preferably located in the needle punched or not punched base cloth in order to increase the stress in elongation and the tensile strength.
  • Thermal bonding between the filaments is performed by the method described hereinafter, that is, the method wherein the base cloth is introduced to a heat embossing machine using a couple of embossing rolls or a couple of embossing roll and flat roll giving thermal bonding of the filaments at the projecting point of the embossing roll, the method wherein the base cloth is introduced to a couple of flat roll giving thermal bonding to only the filaments on the surface of the base cloth, and the method wherein heated air is flown to the base cloth giving thermal bonding at the intersection point.
  • the method wherein the cloth is introduced between the two rolls can control the thickness of the base cloth.
  • the filaments are bonded partially with heat and pressure using embossing rolls.
  • heat boding temperature and heat bonded area ratio are important factors.
  • the temperature for bonding with heat and pressure should be set from (Tm-50) °C to (Tm-5) °C where Tm is the melting point of the polymer with low melting point. If the bonding temperature of the rolls is set to be lower than (Tm-50) °C, the polymer with low melting point is melted insufficiently causing low bonding strength between the filaments.
  • the mechanical property of the base cloth becomes poor and at the same time the bonded area is easily broken and the layers in the base cloth peels off each other easily by the shock of tufting action of needle. And as a result, a base cloth with inferior property is obtained.
  • the temperature of the rolls is set to be higher than (Tm-5) °C, the melted polymer with low melting point sticks to an apparatus for bonding with heat and pressure, causing the resulting operability and processability to be extremely poor.
  • the polymer with high melting point is also melted or softened with the excessively high temperature of the roll, and the base cloth obtained becomes extremely stiff and coarse. Therefore, the friction resistance is increased when the tufting needle penetrates the base cloth.
  • the bonded area ratio should be 4 to 40 percent.
  • the bonded area ratio means the ratio of the bonded area to the whole area of the nonwoven fabric. If the ratio is less than 4 percent, the bonded area is too small in the whole area of the nonwoven fabric. In this case, the base cloth cannot obtain enough strength against tensile stress which works to the cloth during the following process such as tufting, dyeing and backing. On the other hand, if the ratio is higher than 40 percent, the mobility of the filament between the bonded areas is decreased, and it becomes difficult for the filament to follow needle motion and the filament is broken. Therefore, the tensile strength of the base cloth in the tufted carpet is decreased.
  • the shape of the top projecting point is equal to the shape of the bonded are of the nonwoven fabric. The shape is not especially limited, and it is possible to use shape of round, elliptical, rhombus, triangle, T shape, oxford frame, rectangle, square and so forth.
  • the area of the top projecting point is preferably approximately 0.1 to 1.0 mm 2 .
  • linear pressure of approximately 100 to 900 N/cm in the bonding with heat and pressure.
  • a binder resin is attached to the base cloth in order to adhere the contact point between the filaments by the binder resin.
  • the amount of the applied binder resin (solid deposit amount) is preferably 2 to 15 percent by weight of the total weight of the base close for the tufted carpet. If the deposit amount of the resin is less than 2 percent by weight, the effect of using binder resin is not performed. On the other hand, if the deposit amount is more than 15 percent by weight, the amount of the resin between the filaments becomes excessive. Therefore, the mobility of the filament is limited during the tufting process and the tufting needle cannot easily penetrate the base cloth, and the flexibility of the tufted carpet has a tendency of becoming poor.
  • the binder resin As the binder resin, the above described poly lactic acid based polymer for the base cloth is preferably used. Or, poly vinyl alcohol, polysaccharides that is natural polymer such as starch, proteins and chitosans may be used. Besides, monomers such as methyl acrylate, ehtyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, acrylonitrile and styrene are used in the range that biodegradability is not damaged.
  • the total weight of the base close for the tufted carpet of the present invention is set as desired and preferably is 50 to 150 g/m 2 by weight in general. If the weight is less than 50 g/m 2 , the mechanical strength of the base cloth decreases. Because the total amount of the filament in the base cloth is small, the retention power for the tufting yarn to the base cloth is not enough, causing falling off of tufting yarn during the tufting process. On the other hand, if the weight is more than 150 g/m 2 , the total amount of the filament in the base cloth is excessive and therefore evenness in height of the pile yarn cannot be obtained or tufting stitch becomes uneven. At the same time, the carpet obtained has excessive performance and is not economical.
  • a biodegradable tufting yarn is implanted by tufting method on the base cloth.
  • the biodegradable fiber configuring the tufting yarn is selected from the following yarn, that is, yarn made of poly lactic acid based polymer used in the base cloth mentioned above, yarn made of aliphatic polyester, natural fiber and regenerated fiber.
  • Cotton wool and linen are suitable as natural fiber, and rayon, acetate and rayon obtained by the solvent spinning method are suitable as regenerated fiber.
  • Cotton, wool and regenerated fiber are preferably used to obtain excellent water absorbing property and touch. From the standpoint of recycling, the same type of material used for the base cloth that is poly lactic acid based polymer is preferably used and more preferably bulky textured yarn is used for tufting yarn.
  • backing layer is attached in order to fasten the pile yarn and to reinforce the carpet in the back side of the tufted pile yarn.
  • the known bitumen ethylene vinyl acetate resin, polyurethane resin are preferably used.
  • poly lactic acid based polymer used in the above described base cloth and aliphatic polyester are preferably used.
  • the following method is used, that is, the coating or impregnating method wherein the base cloth is coated or impregnated by the melted resin, the foam method wherein resin solution foam is coated in the back face of the base cloth and then dried, and the powder method wherein the power resin is melted and simultaneously coated on the surface of the nonwoven fabric.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll to obtain the nonwoven fabric of filament with monocomponent structure under the condition of; embossing pattern: point,
  • the nonwoven fabric was treated by dimethyl-polysiloxane aqueous emulsion to have 0.5 percent deposit thereof by weight of the nonwoven fabric, and moreover 12 percent by weight of binder, consisting of aqueous solution of poly lactic acid, was given on the whole weight of the base cloth.
  • the base cloth for tufted carpet with weight of 100 g/m 2 was obtained.
  • the filament was drawn between the take up roll and a drawing roll located under the take up roll. Then, the drawn filament was passed through heated and a humidified crimping machine located under the drawing roll and was processed by treatment of relaxing and heating to obtain poly lactic acid pile yarn of 1430 dtex / 64 filaments.
  • the poly lactic acid pile yarn obtained was tufted using a tufting machine to the base cloth of poly lactic acid for tufted carpet under the condition of gauge of 1/10, stitch of 10/2.54 cm and loop pile height of 6 mm.
  • the extruded amount of PLA-1 from the spinning nozzle was modified to obtain filaments of single filament fineness of 6.6 dtex.
  • Other conditions were the same as Example 1 and base cloth for tufted carpet and resulting tufted carpet were obtained.
  • the extruded amount of PLA-1 from the spinning nozzle was modified and the drawing speed by the air sucker was changed to 5000 m/minute to obtain filaments of single filament fineness of 6.6 dtex.
  • Other conditions were the same as Example 1 and base cloth for tufted carpet and resulting tufted carpet were obtained.
  • the extruded amount of PLA-1 from the spinning nozzle was modified and the drawing speed by the air sucker was changed to 6000 m/minute to obtain filaments of single filament fineness of 6.6 dtex.
  • Other conditions were the same as Example 1 and base cloth for tufted carpet and resulting tufted carpet were obtained.
  • binder of aqueous solution of poly lactic acid in Example 1 instead of the binder of aqueous solution of poly lactic acid in Example 1, binder consisting of poly vinyl alcohol aqueous solution was given to the nonwoven fabric of monocomcomponent filament in Example 1 so as to contain 12 percent by weight of the binder, and base cloth for tufted carpet was obtained. Other conditions were the same as Example 1 and base cloth for tufted carpet and resulting tufted carpet were obtained.
  • binder of aqueous solution of poly lactic acid in Example 1 instead of the binder of aqueous solution of poly lactic acid in Example 1, binder consisting of acrylate aqueous solution was given to the nonwoven fabric of monocomponent filament in Example 1 to contain 6 percent by weight of the binder, and base cloth for tufted carpet of weight of 100 g/m 2 was obtained. Other conditions were the same as Example 1 and base cloth for tufted carpet and resulting tufted carpet were obtained.
  • Example 2 The following changes were made as compared with Example 1, and tufted carpet was obtained.
  • the temperature of the embossing roll was set to 80 °C and nonwoven fabric of filament was obtained by temporary bonding with heat and pressure. Then, the obtained nonwoven fabric was passed through a needle punching machine with needle of RPD36#. The nonwoven fabric was punched by needle density of 60 punches/cm 2 to obtain a punched web. The punched web was then bonded by heat and pressure at temperature of 110 °C.
  • the binder containing poly lactic acid aqueous solution was given to the web to have 12 percent by weight of the binder to obtain base cloth for tufted carpet.
  • a nonwoven fabric using sheath-core type filament was manufactured.
  • the filament was drawn and made finer by air sucker which was set under the spinning nozzle at drafting speed of 5300 m/minute. Filaments were spreaded open each other and deposited as a filament web on a collecting surface of a traveling conveyor. The fineness of the single filament was 6.6 dtex.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll under the condition of;
  • the filament web was treated by dimethyl-polysiloxane aqueous emulsion to have 0.5 percent deposit thereof by weight of the filament.
  • a nonwoven fabric consisting of the sheath-core type filament with weight of 100 g/m 2 was obtained. This nonwoven fabric was used as base cloth for tufted carpet.
  • the extruded amount of PLA-1 and PLA-2 from the spinning nozzle was modified and controlled to give the ratio of (PLA-1 / PLA-2) of 50/50 percent by weight.
  • Other conditions were the same as Example 8 and base cloth and resulting tufted carpet were obtained.
  • the extruded amount of PLA-1 and PLA-2 from the spinning nozzle was modified and controlled to give the ratio of (PLA-1 / PLA-2) of 30/70 percent by weight.
  • Other conditions were the same as Example 8 and base cloth and resulting tufted carpet were obtained.
  • Example 8 Compared with the polymer of Example 8, the polymer of the sheath in the sheath-core structure filament was changed.
  • the same polymer as in Example 8 was used in the core. These two polymers were extruded from the spinning nozzle with sheath-core structure.
  • the ratio of (PLA-1 / PLA-3) was adjusted to 50/50 percent by weight.
  • the drafting speed of an air sucker was set to 5200 m/minute and the temperature of the embossing roll was 90 °C.
  • Other conditions were the same as Example 8 and base cloth and resulting tufted carpet were
  • a multilobed structure was adopted as cross-section of the filament.
  • PLA-1 used in Example 1 and PLA-2 used in Example 8 were melted at 210 °C and extruded from the spinning nozzle to obtain the filament wherein PLA-1 was located in the core and PLA-2 was located in the 6 lobes of sheath by the ratio of (PLA-1 / PLA-2) of 50/50 of weight ratio.
  • the filament shown by FIG. 1 was spun as having a cross-section of 6-lobed sheath.
  • the extruded filament was quenched by a known quenching device, the filament was drawn and made finer by an air sucker which was set under the spinning nozzle at a drafting speed of 5300 m/minute.
  • the filaments were spreaded open each other and deposited as a filament web on a collecting surface of a traveling conveyor. The fineness of the single filament constituting the web was 6.6 dtex.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll under the condition of;
  • the filament web was treated by dimethyl-polysiloxane emulsion to have 0.5 percent deposit thereof by weight of the filament, and a nonwoven fabric with a 6 lobe type filament with weight of 100 g/m 2 was obtained. This nonwoven fabric was used as base cloth. And then, tufted carpet was obtained under the same condition as Example 8.
  • PLA-1 in Example 1 and PLA-2 in Example 8 were melted at 210 °C and melt spun using a spinning nozzle for mixed filaments with mixing ratio of (PLA-1 / PLA-2) of 70/30 percent by weight. After the extruded filaments were quenched using a known quenching device, the filaments were drawn and made finer by an air sucker which was set under the spinning nozzle at drafting speed of 5300 m/minute. The filaments were spreaded open each other and deposited as a filament web on a collecting surface of a traveling conveyor. The fineness of the filament consisting of PLA-1 and that of the filament consisting of PLA-2 were 6.6 dtex respectively.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll under the condition of;
  • the filament web was treated by dimethyl-polysiloxane emulsion to have 0.5 percent deposit thereof by weight of the filament and a nonwoven fabric of the mixed filaments with weight of 100 g/m 2 was obtained.
  • Tufted carpet was obtained under the same condition as Example 8.
  • Example 8 The filament web obtained in Example 8 was processed by thermal through treatment using a continuous treating machine at 155 °C. The treated web was then treated by dimethyl-polysiloxane aqueous emulsion to have 0.5 percent deposit thereof by weight of the filament and a nonwoven fabric of the sheath-core type filament with weight of 100 g/m 2 was obtained. Tufted carpet was obtained under the same condition as Example 8.
  • the base cloth for tufted carpet consisting of filaments was manufactured by spin draw take up method using PLA-1 in Example 1.
  • PLA-1 was melted at 210 °C and was melt spun by being extruded through a monocomponent structure spinning nozzle.
  • the filament was led to a first roll (speed of 1200 m/ minute and temperature of 80 °C) located under the nozzle.
  • the filament was drawn between the first roll and a second roll of 100 °C at a speed of 3000 m/ minute, and then led to a third roll (speed of 3000 m/minute and temperature of 150 °C) to be heated at constant length.
  • the filaments drawn at the drawing ratio of 2.5 were led to an air sucker and were spreaded open each other and deposited as a filament web on a collecting surface of a traveling conveyor.
  • the fineness of the single filament was 6.6 dtex.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll under the condition of;
  • the web was treated by dimethyl-polysiloxane emulsion to have 0.5 percent deposit thereof by weight of the filament and a nonwoven fabric of the monocomponent filament with weight of 100 g/m 2 was obtained.
  • Other conditions were the same as Example 1 and base cloth and resulting tufted carpet were obtained.
  • the base cloth obtained in Example 1 to Example 15 had excellent mechanical stability and heat stability and also had excellent processability for carpet. Especially excellent and stable productivity was performed to manufacture the base cloth obtained in Example 8 to Example 14 consisting of the multicomponent filaments. The filaments were adhered together firmly, nevertheless the mobility of the filament in the base cloth was maintained. As a result, the strength retention after tufting was excellent. The tufted carpet obtained from these base cloth had superior biodegradability.
  • Pile yarn consisting of nylon 6 of 1430 dtex / 64 filaments was tufted to the base cloth obtained in Example 8 under the condition of gauge of 1/10, stitch 10 / 2.54 cm and loop pile height of 6 mm using tufting machine. Then, polyethylene resin was extruded to make film. The film was laminated to the backside of the tufted base cloth to obtain tufted carpet. In this method, the strength retention was equal to or more than 80 percent. There could be observed no void and the backing layer was uniformly attached to the base cloth.
  • the component parts (the backing layer, the pile yarn and the base cloth) could be separated. Only the base cloth with biodegradability could be biodegraded.
  • the extruded amount of PLA-1 was modified and the drawing speed of the air sucker was changed to 2300 m/minute to obtain filaments of single filament fineness of 6.6 dtex.
  • Other conditions were the same as Example 1, and base cloth and resulting tufted carpet were obtained.
  • the extruded amount of PLA-1 was modified and the drawing speed of the air sucker was changed to 7200 m/minute to obtain filaments of single filament fineness of 6.6 dtex.
  • Other conditions were the same as Example 1 and melt spinning was attempted. However, there occurred a plurality of filament breakage and it was impossible to obtain nonwoven fabric of the filament.
  • Polypropylene with melting point of 160 °C and MFR of 40 g/ 10 minutes was melted at 230 °C and spun using the monocomponent structure spinning nozzle.
  • the filament was drawn and made finer by an air sucker which was set under the spinning nozzle at a drafting speed of 3800 m/minute.
  • the filaments were spreaded open each other and deposited as a filament web on a collecting surface of a traveling conveyor. The fineness of this single filament constituting the web was 6.6 dtex.
  • the filament web was partially bonded with heat and pressure using a heated embossing roll under the condition of;
  • the filament web was treated by dimethyl-polysiloxane emulsion to have 0.5 percent deposit thereof by weight of the filament, and a nonwoven fabric of the monocomponent filament with weight of 100 g/m 2 was obtained.
  • the nonwoven fabric of the monocomponent filament was dipped in a binder of acrylate aqueous solution in Example 6 to obtain base cloth with 6 percent by weight of acrylate binder deposit.
  • polypropylene with melting point of 160 °C and MFR of 20 g/10 minutes was melted at 230 °C, extruded through a monocomponent structure spinning nozzle, and spun via a take up roll.
  • the filament was drawn between the take up roll and a drawing roll located under the take up roll. Then, the drawn filament was passed through the heated and humidified crimping machine located under the drawing roll and was processed by the treatment of relaxing and heating to obtain polypropylene pile yarn of 1430 dtex /64 filaments.
  • the pile yarn was tufted to the base cloth consisting of polypropylene filament. Other conditions were the same as Example 1 and tufted carpet were obtained.
  • the tufted carpet in comparative Example 3 did not have biodegradability and as a result, the carpet had a problem when disposed. Moreover, due to cyclic compression, the pile fell down causing poor appearance.

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  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Carpets (AREA)
EP00919168A 1999-04-26 2000-04-25 Tufting-teppich mit einem grundgewebe Expired - Lifetime EP1130149B1 (de)

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JP11788499 1999-04-26
JP11788499 1999-04-26
PCT/JP2000/002685 WO2000065140A1 (fr) 1999-04-26 2000-04-25 Tissu de fond pour tapis tufte et tapis tufte fabrique a partir de ce dernier

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EP2175055A3 (de) * 2008-08-14 2010-09-15 Luxilon Industries, naamloze vennootschap Monofilamentfaden
CN108697254A (zh) * 2016-04-11 2018-10-23 尤尼吉可株式会社 簇绒地毯用一次底布和其制造方法
KR20180134890A (ko) * 2016-04-11 2018-12-19 유니띠까 가부시키가이샤 터프테드 카페트용 1차 기포 및 그 제조방법
EP3443875A4 (de) * 2016-04-11 2019-02-20 Unitika Ltd. Primäres grundgewebe für tuffteppich und verfahren zur herstellung davon
US10876239B2 (en) 2016-04-11 2020-12-29 Unitika Ltd. Primary base fabric for tufted carpet, and method of manufacturing same

Also Published As

Publication number Publication date
EP1130149A4 (de) 2005-09-14
KR20010053138A (ko) 2001-06-25
WO2000065140A1 (fr) 2000-11-02
EP1130149B1 (de) 2009-06-17
JP4623833B2 (ja) 2011-02-02
DE60042394D1 (de) 2009-07-30

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