CN104842843A - 车用地垫及其制备方法 - Google Patents

车用地垫及其制备方法 Download PDF

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CN104842843A
CN104842843A CN201510272364.XA CN201510272364A CN104842843A CN 104842843 A CN104842843 A CN 104842843A CN 201510272364 A CN201510272364 A CN 201510272364A CN 104842843 A CN104842843 A CN 104842843A
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layer
cloth
ground mat
burr
base cloth
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胡继艳
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Guangzhou Legend Car Assessories Co Ltd
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Guangzhou Legend Car Assessories Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
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    • B32—LAYERED PRODUCTS
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/00—Coating on the layer surface
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
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Abstract

本发明公开了一种车用地垫及其制备方法，车用地垫包括纤维层、活性炭纤层、基布层、防滑毛刺布层及热熔底胶层；所述纤维层、活性炭纤层、基布层及防滑毛刺布层由上至下依次顺序叠置，所述纤维层、活性炭纤层、基布层及防滑毛刺布层之间通过簇绒方式使得相邻的两层连接后形成毯面，所述热熔底胶层涂覆于所述毯面。本发明涉及的车用地垫既可以保证产品本身的材料和工艺达到无毒无味的标准，又能够改善车内空气质量、保证车内乘车人员的身体健康。

Description

车用地垫及其制备方法
技术领域
本发明涉及汽车配件领域，特别是涉及一种车用地垫及其制备方法。
背景技术
目前市场上流通的车垫产品大部分达不到基本的环保要求，在消费者使用时会出现明显的异味甚至刺激性的气味，会影响到消费者的健康，近期有出现些无明显异味的新产品，但也只能保持这个产品本身无味，做不到保护消费者的健康，产品本身不能改善车内的空气质量。
发明内容
基于此，有必要提供一种既可以保证产品本身的材料和工艺达到无毒无味的标准，满足其防尘、除污、隔音等基本的使用功能，又能够改善车内空气质量、保证车内乘车人员的身体健康的车用地垫。
一种车用地垫，包括纤维层、活性炭纤层、基布层、防滑毛刺布层及热熔底胶层；
所述纤维层、活性炭纤层、基布层及防滑毛刺布层由上至下依次顺序叠置，所述纤维层、活性炭纤层、基布层及防滑毛刺布层之间通过簇绒方式使得相邻的两层连接后形成毯面；
所述热熔底胶层涂覆于所述毯面。
在其中一个实施例中，所述纤维层采用PP或者PE材料制成。
在其中一个实施例中，所述基布层采用PP或者PE材料制成，所述基布层的克重为120～240g/m2。
在其中一个实施例中，所述防滑毛刺布层采用绦纶与尼龙材料结合制成，所述防滑毛刺布层的克重为100～150g/m2。
在其中一个实施例中，所述纤维层为多个纤维丝，所述多个纤维丝的一端连接于所述活性炭纤层，另一端背离活性炭纤层。
在其中一个实施例中，所述纤维丝呈螺旋状弯曲。
在其中一个实施例中，所述纤维层的多个纤维丝布满所述活性碳纤层，且均布于所述活性碳纤层，所述纤维丝的密度为46200～54600针/m2，相邻排的纤维丝间距为3.175mm～4.763mm。
在其中一个实施例中，所述活性炭纤层在所述纤维层与所述基布层之间的厚度为2mm～5mm。
在其中一个实施例中，所述防滑毛刺布层具有多个毛刺，所述毛刺的密度为15～20万针/m2，相邻排的毛刺间距为2.5mm～5.0mm。
本发明的另一目的在于提供一种车用地垫的制备方法。
一种车用地垫的制备方法，包括如下步骤：
在机床床面上依次叠放活性炭纤层、基布层、防滑毛刺布层，将活性炭纤层、基布层、防滑毛刺布层通过簇绒的方式植入纤维丝后形成面料层毯面；
将热熔底胶层涂覆在毯面上成型卷材成品；
修整纤维层及防滑毛刺布层；
将地垫裁切成所需的形状。
本发明涉及的车用地垫，通过纤维层、活性炭纤层、基布层、防滑毛刺布层及毛刺层之间的配合，使得本车用地垫产品本身无异味，同时该车用地垫产品还可以吸收、过滤车内(尤其是新车)原有气味以改善车内空气质量，达到保护消费者身心健康的目的。
本发明涉及的车用地垫，安全无毒；清洗容易，常规保养采用吸尘处理或湿布擦拭，必要时只需要用清水冲洗即可；使用寿命长。
本发明涉及的车用地垫，产品结构安全，采用产品底部植入防滑针布的工艺方法达到产品防滑功能，符合汽车使用的安全要求，不产生打滑、移位现象。
本发明涉及的车用地垫，产品材料安全，市面上的大部分产品选用PVC、PU材料为主材进行车垫产品的生产，本司选用PP\PE材料作为主材，材料本身无明显异味或刺激性气味。
本发明涉及的车用地垫，产品工艺环保，产品生产过程中不使用任何胶粘剂进行复合；同时通过加入碳纤滤材以达到空气净化的效果。
本发明涉及的车用地垫，加入碳纤层的车垫产品可以达到有选择性地吸附有害气体，比如常见的甲醛、甲苯、二甲苯、二氧化碳等有害气体及刺激性异味可以有效过滤。产品在使用过程中可以通过汽车自有的空调制冷或加热循环功能对车垫产生加热或干燥的效果，达到让已吸附的有害气体脱离活性炭，以此保持其吸附性能持续有效，可保持多次再生使用。
本发明涉及的车用地垫的制备方法，工序简单，操作简便，无需胶水，对车间内工人的身体健康有保证。
附图说明
图1为本发明实施例弯曲状纤维丝时的车用地垫示意图；
图2为本发明实施例螺旋状纤维丝时的车用地垫示意图。
附图标记说明
100、纤维层；101、纤维丝；200、活性炭纤层；300、基布层；400、防滑毛刺布；500、毛刺层；501、毛刺。
具体实施方式
为了便于理解本发明，下面将参照相关附图对本发明进行更全面的描述。附图中给出了本发明的较佳实施例。但是，本发明可以以许多不同的形式来实现，并不限于本文所描述的实施例。相反地，提供这些实施例的目的是使对本发明的公开内容的理解更加透彻全面。
需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。
除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。本文所使用的术语“和/或”包括一个或多个相关的所列项目的任意的和所有的组合。
一种车用地垫，参见图1及图2所示，包括纤维层100、活性炭纤层200、基布层300、防滑毛刺布层，所述防滑毛刺布层具有防滑毛刺布400及毛刺层500，所述毛刺层500为多个针刺状的毛刺501组成；所述纤维层100为多个纤维丝101。
所述纤维层100、活性炭纤层200、基布层300、防滑毛刺布层由上至下依次顺序叠置，所述纤维层100、活性炭纤层200、基布层300及防滑毛刺布层400之间通过簇绒的方式织造成为整体叠加的毯面；然后通过在毯面上涂覆热熔底胶层形成完整产品(车用地垫)。也即是上面4层(纤维层100、活性炭纤层200、基布层300、防滑毛刺布层)先通过簇绒工艺形成面料层毯面，然后通过热熔底胶层涂覆在毯面上成型卷材成品，其中簇绒过程是纤维丝101依次穿过碳纤层、基布层及防滑毛刺布400形成毯面。
多个所述毛刺501穿过所述防滑毛刺布400簇绒于所述基布层300。所述毛刺层500的毛刺501布满所述防滑毛刺布400，且均布于所述防滑毛刺布400，所述毛刺501的密度为15～20万针/m2，相邻排的毛刺501间距为2.5mm～5.0mm。
所述纤维层100采用PP或者PE材料制成。所述基布层300采用PP或者PE材料制成，所述基布层300的克重为120～240g/m2。所述防滑毛刺布400采用绦纶和尼龙材料制成，所述防滑毛刺布400的克重为为100～150g/m2。所述防滑毛刺布400采用绦纶制成，毛刺层500采用尼龙材料制成，形成一个整体层防滑毛刺布层，所述防滑毛刺布400、毛刺层500为便于识别而分开标记定义，实为一个整体层。也即防滑毛刺布层是一个面为布(防滑毛刺布400)，一个面为刺(毛刺501)的整体材料，在布(防滑毛刺布400)、刺(毛刺501)叠加后直接形成了布面(防滑毛刺布400)与基布层300的层叠，同时其底面为刺底(毛刺501)的整体一体式结构。
所述多个纤维丝101的一端连接于所述活性炭纤层200，另一端背离活性炭纤层200，所述纤维丝101呈不规则弯曲参见图1所示，或者所述纤维丝101呈螺旋状弯曲，参见图2所示。所述纤维层100的多个纤维丝101布满所述活性碳纤层，且均布于所述活性碳纤层，所述纤维丝101的密度为46200～54600针/m2，相邻排的纤维丝101间距为3.175mm～4.763mm。
所述活性炭纤层200在所述纤维层100与所述基布层300之间的厚度为2mm～5mm。
本实施例涉及的车用地垫，在生产过程中涉及的车用地垫的制备方法，包括如下步骤：
在机床床面上依次叠放活性炭纤层200、基布层300、防滑毛刺布层400，将活性炭纤层200、基布层300、防滑毛刺布层400通过簇绒的方式实现面料层毯面，也即将纤维层100的纤维丝101通过簇绒方式依次穿过活性炭纤层200、基布层300，最后穿过防滑毛刺布400，防滑毛刺布层是一个面为布(防滑毛刺布400)，一个面为刺(毛刺501)的整体材料，在布(防滑毛刺布400)、刺(毛刺501)叠加后直接形成了布面(防滑毛刺布400)与基布层300的层叠，同时其底面为刺底(毛刺501)的整体一体式结构；
通过热熔底胶层涂覆在毯面上成型卷材成品；
修整纤维层100及防滑毛刺布层的毛刺501；
将地垫裁切成各个车型的汽车内部地板上所匹配的形状。
本发明涉及的车用地垫，加入的活性碳纤层的车垫产品可以达到有选择性地吸附有害气体，比如常见的甲醛、甲苯、二甲苯、二氧化碳等有害气体及刺激性异味可以有效过滤。产品在使用过程中可以通过汽车自有的空调制冷或加热循环功能对车垫产生加热或干燥的效果，达到让已吸附的有害气体脱离活性炭，以此保持其吸附性能持续有效，可保持多次再生使用。
本发明涉及的车用地垫，主要有害气体去除指标(平衡吸附量mg/g)：
甲苯320；二甲苯290；甲醛320；二氧化碳830。
本发明涉及的车用地垫，通过纤维层、活性炭纤层、基布层、防滑毛刺布层及毛刺层之间的配合，使得本车用地垫产品本身无异味，同时该车用地垫产品还可以吸收、过滤车内(尤其是新车)原有气味以改善车内空气质量，达到保护消费者身心健康的目的。
本发明涉及的车用地垫，安全无毒；清洗容易，常规采用吸尘处理或湿布擦拭，必要时只需要用清水冲洗即可；使用寿命长。
本发明涉及的车用地垫，产品结构安全，采用产品底部植入防滑针布的工艺方法达到产品防滑功能，符合汽车使用的安全要求，不产生打滑、移位现象。
本发明涉及的车用地垫，产品材料安全，市面上的大部分产品选用PVC、PU材料为主材进行车垫产品的生产，本司选用PP\PE材料作为主材，材料本身无明显异味或刺激性气味。
本发明涉及的车用地垫，产品工艺环保，产品生产过程中不使用任何胶粘剂进行复合，同时通过加入碳纤滤材以达到空气净化的效果。
本发明涉及的车用地垫，加入碳纤层的车垫产品可以达到有选择性地吸附有害气体，比如常见的甲醛、甲苯、二甲苯、二氧化碳等有害气体及刺激性异味可以有效过滤。产品在使用过程中可以通过汽车自有的空调制冷或加热循环功能对车垫产生加热或干燥的效果，达到让已吸附的有害气体脱离活性炭，以此保持其吸附性能持续有效，可保持多次再生使用。
本发明涉及的车用地垫的制备方法，工序简单，操作简便，无需胶水，对车间内工人的身体健康有保证。
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对本发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (10)

1.一种车用地垫，其特征在于，包括纤维层、活性炭纤层、基布层、防滑毛刺布层及热熔底胶层；
所述纤维层、活性炭纤层、基布层及防滑毛刺布层由上至下依次顺序叠置，所述纤维层、活性炭纤层、基布层及防滑毛刺布层之间通过簇绒方式使得相邻的两层连接后形成毯面；
所述热熔底胶层涂覆于所述毯面。
2.根据权利要求1所述的车用地垫，其特征在于，所述纤维层采用PP或者PE材料制成。
3.根据权利要求1所述的车用地垫，其特征在于，所述基布层采用PP或者PE材料制成，所述基布层的克重为120～240g/m2。
4.根据权利要求1-3任意一项所述的车用地垫，其特征在于，所述防滑毛刺布层采用绦纶与尼龙材料结合制成，所述防滑毛刺布层的克重为100～150g/m2。
5.根据权利要求1-3任意一项所述的车用地垫，其特征在于，所述纤维层为多个纤维丝，所述多个纤维丝的一端连接于所述活性炭纤层，另一端背离活性炭纤层。
6.根据权利要求5所述的车用地垫，其特征在于，所述纤维丝呈螺旋状弯曲。
7.根据权利要求5所述的车用地垫，其特征在于，所述纤维层的多个纤维丝布满所述活性碳纤层，且均布于所述活性碳纤层，所述纤维丝的密度为46200～54600针/m2，相邻排的纤维丝间距为3.175mm～4.763mm。
8.根据权利要求1-3任意一项所述的车用地垫，其特征在于，所述活性炭纤层在所述纤维层与所述基布层之间的厚度为2mm～5mm。
9.根据权利要求1-3任意一项所述的车用地垫，其特征在于，所述防滑毛刺布层具有多个毛刺，所述毛刺的密度为15～20万针/m2，相邻排的毛刺间距为2.5mm～5.0mm。
10.一种车用地垫的制备方法，其特征在于，包括如下步骤：
在机床床面上依次叠放活性炭纤层、基布层、防滑毛刺布层，将活性炭纤层、基布层、防滑毛刺布层通过簇绒的方式植入纤维丝后形成面料层毯面；
将热熔底胶层涂覆在毯面上成型卷材成品；
修整纤维层及防滑毛刺布层；
将地垫裁切成所需的形状。
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