DE102007004146A1 - Non-slip mat for automobile floors, has underside with upper and lower needled non-woven layers, consolidated and bonded together by fused polyethylene fiber components - Google Patents

Abstract

An automobile floor mat has a non-slip underside comprising upper (a) and lower (b) layers of needled non-woven. Layer (a) is of thermoplastic fibers; and layer (b) is of a blend of polypropylene (PP) and polyethylene (PE) fibers or of PP/PE two-component fibers (optionally blended with PP and/or PE fibers). The layers are consolidated and bonded together by fused PE components, and layer (b) is thermally embossed to improve the non-slip effect. An independent claim is included for the production of the mat, by bonding the layers (a) and (b) together by thermal treatment in a press and simultaneously or subsequently carrying out thermal embossing of layer (b).

Description

The The invention relates to a floor mat for motor vehicles with anti-slip bottom and on a manufacturing process such a doormat.

Foot mats for motor vehicles, but also cargo mats, can be found in Universal or fit versatile use. Most notably in the case of the doormat in front of the driver's seat it is important that slippage of the doormat is prevented, so that the pedals of the motor vehicle are not obstructed, which is a considerable Risk of accident. For this purpose, on the one hand Fastening systems used the doormat with the Connecting vehicle floor, the connection is predominantly is releasably designed to take out the doormat To allow cleaning or the like. One Such fastening system consists of Velcro plates with Velcro hooks, attached to the vehicle floor, for example, are glued, the doormats then in the appropriate places have velor surfaces glued on the underside, with the Velcro hook enter a releasable Velcro connection can. In addition, it is known to doormats the back with non-slip materials, such as Sodium-silicone fluoride latex, polyurethane foam, rubber or rubber granules too coat or to flock. A largely safe slip resistance can be in practice usually only by the combination of fastening systems and anti-slip bottom reach the doormat. It is disadvantageous that for the anti-slip coating in the production of the doormat additional work steps are required and additional Materials are needed. Also on the coating put attached velor surfaces of the fastening systems an additional effort in production and material. In addition these floor mats no longer sorted, so they very difficult if ever recyclable.

From the DE 297 06 968 U1 For example, a two-layered thermoplastic fiber needle punch web is known in which the first layer is a blend of polypropylene (PP) fibers and polyethylene (PE) fibers, the second layer is a blend of PP fibers and PE fibers; or from biconstituent fibers consisting of a mixture of PP and PE; or a mixture of these biconstituent fibers and PP fibers and / or PE fibers, and the two layers are solidified and interconnected both by needling and by melted or melted fibers or fiber parts consisting of the PE portion of the two layers.

The DE 198 12 925 A1 describes the transformation of carpet structures based on multilayer structured needled nonwovens from mixtures of polyolefin fibers, as described, for example, in US Pat DE 297 06 968 U1 are described to automobile moldings with the required according to the technical delivery conditions of the automotive industry dimensional stability used as molded car mats in automotive production, such as car mats on the car floor, in the trunk or for large-scale deformation, such. B. wheel arch or large-scale moldings in the trunk or the entire floor part in the passenger compartment, the three-dimensional shapes of the vehicle interior body, such. B. shaping over Kardantunnel etc. must be adapted.

From the DE 103 36 459 A1 For example, floor coverings with a structured surface are known, which have a top layer and a bottom layer, wherein these are welded together by means of a weldable medium. The underlayer of the floor coverings has a coating of sodium silicone fluoride latex, polyurethane foam, rubber or rubber granulate.

Of the Invention is based on the object, a doormat for Motor vehicles with anti-slip bottom and a procedure to specify for the production, wherein the production is simple and with perform as few different materials is.

Solved This object is achieved by the features of the independent claims.

• a) ein Nadelvlies als Oberschicht, das aus thermoplastischen Fasern besteht, und
• b) ein Nadelvlies als Unterschicht, das aus einer Mischung aus Polypropylen-Fasern und Polyethylen-Fasern; oder aus Bikonstituentenfasern bestehend aus einer Mischung von Polypropylen und Polyethylen; oder aus einer Mischung dieser Bikonstituentenfasern und Polypropylen-Fasern und/oder Polyethylen-Fasern besteht,
• c) wobei die beiden Schichten durch geschmolzene oder angeschmolzene Fasern bzw. Faserteile bestehend aus dem Polyethylen-Anteil der beiden Schichten verfestigt und miteinander verbunden sind und
• d) die Unterschicht zur Verbesserung der Rutschsicherheit thermogeprägt ist.

The floor mat according to the invention for motor vehicles with slip-resistant underside comprises

• a) a needle-punched nonwoven as a topsheet consisting of thermoplastic fibers, and
• b) a needle-punched nonwoven fabric made of a blend of polypropylene fibers and polyethylene fibers; or from biconstituent fibers consisting of a blend of polypropylene and polyethylene; or a mixture of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers,
• c) wherein the two layers are solidified and joined together by molten or fused fibers or fiber parts consisting of the polyethylene portion of the two layers and
• d) the underlayer is thermoformed to improve slip resistance.

Due to the thermal embossing of the lower layer from which arise on the underside of the doormat raised and pressed areas, one obtains solely from the material of the lower layer a slip-resistant design of the underside of the Doormat without the need for a coating with another material. At the same time, due to the thermal embossing, there is an increased flexural rigidity of the floor mat required by automobile manufacturers without the need for a chemical hardening method. The needle felt may be coarse-grained or fine-fiber depending on the requirements.

The used polypropylene (PP) and polyethylene (PE) fibers and the biconstituent fibers are commercially available, for example ASOTA. L, D, G (PP fibers), ASOTA H, N (PE fibers) and ASOTA LV 4506 (biconstituent fiber) from Asota. The biconstituent fibers usually consist of about 40 to 55 wt.%, Preferably 45 to 50 wt.% PP and about 60 to 45 wt.%, Preferably 55 to 50 Weight% PE. Both PP and homopolymers come as PP its copolymers, in particular with ethylene in question. Come as a PE HDPE, LLDPE and LDPE in question. The type and amount of used Fibers depend primarily on the required properties the needle fleece. Those used as upper and lower layers Needle fleeces can be made according to the existing needle technology be formed by needling a fiber mixture. Appropriate Needle nonwovens are also commercially available. Depending on requirements and design of the final product can thereby fibers with different fiber thickness, different lengths, or fibers are mixed with different properties.

• a) ein Nadelvlies als Oberschicht, das aus thermoplastischen Fasern besteht, mit einem Nadelvlies als Unterschicht, das aus einer Mischung aus Polypropylen-Fasern und Polyethylen-Fasern; oder aus Bikonstituentenfasern bestehend aus einer Mischung von Polypropylen und Polyethylen; oder aus einer Mischung dieser Bikonstituentenfasern und Polypropylen-Fasern und/oder Polyethylen-Fasern besteht, in einer Presse miteinander verbunden werden, indem in der Presse eine thermische Behandlung vorgenommen wird, wobei die Polyethylen-Anteile schmelzen, und anschließend
• b) eine Thermoprägung der Unterschicht zur Verbesserung der Rutschsicherheit erfolgt.

According to a method for producing a floor mat for motor vehicles with slip-resistant underside according to the invention it is provided that

• a) a needle-punched non-woven fabric consisting of thermoplastic fibers with a needle-punched non-woven fabric as a lower layer, which consists of a mixture of polypropylene fibers and polyethylene fibers; or from biconstituent fibers consisting of a blend of polypropylene and polyethylene; or a mixture of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers, are joined together in a press by thermal treatment in the press, the polyethylene portions melting, and subsequently
• b) a thermal embossing of the lower layer to improve the slip resistance takes place.

It This is done first, a compound of the two needle fleece layers and in a subsequent process step, the thermal embossing for Improvement of slip resistance. This procedure is therefore complete especially suitable if the upper layer and lower layer of webs be connected to each other. Following the connection then the individual doormats can be joined from the connected Layers are punched. Thereafter, the thermal embossing is done. In addition to this discontinuous process is also a continuous Production possible.

at another manufacturing method according to the invention take place the connection of the upper class and lower class as well as the Thermal embossing of the lower layer at the same time by a Needle nonwoven as a top layer, which consists of thermoplastic fibers, with a needle felt as a lower layer, which consists of a mixture of Polypropylene fibers and polyethylene fibers; or consisting of biconstituent fibers from a mixture of polypropylene and polyethylene; or from one Blend of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers exists to be interconnected in a press by in the press a thermal treatment is made, the Polyethylene parts melt and at the same time a thermal embossing the lower layer for improving the slip resistance takes place. This method is particularly well suited if from the individual needle fleeces the upper class and the lower class first the forms the individual floor mats are punched. After that can then connect the layers and the thermal embossing of Underlayer done in a single operation.

According to one advantageous development of the invention, the improvement takes place the slip resistance during the thermal embossing the lower class through the formation of a suitable pattern, preferably transversely to the direction of the velor of the lower layer. This results in a particularly good slip resistance. The single ones after embossing, raised areas of the underside the doormat wedge when used in the motor vehicle in the velor of the vehicle floor, allowing slipping the doormat is largely prevented.

The formed by the thermal pattern pattern on the bottom The doormat can be of simple geometric shapes be formed. The exact design of the geometric shapes can thereby to the requirements of the practice, in particular also in vote be adapted to the respective vehicle floor.

According to another embodiment of the invention, the pattern formed by the thermal embossing is formed on the underside in the manner of a tire profile. This results in a secure slip resistance on the one hand and on the other hand offers a particularly attractive optical design with respect to the field of application within a motor vehicle. The running direction of the illustrated Tire profiles is preferably transverse to the direction of the velor of the lower layer.

If in addition to the slip-resistant design of the underside the doormat fastening systems for secure attachment the doormat on the vehicle floor, in particular in the form of Velcro plates with Velcro hooks attached to the vehicle floor, for example, glued are used, it is proposed that the lower layer one adapted geometry for connecting the doormat having with these fasteners. This custom geometry For example, in the form of circular surfaces unaltered velor, the thermographic embossing the lower layer are provided at the places where when installing the doormat in the vehicle, the corresponding Velcro fasteners are located. On these velor surfaces, the Engage hook-and-loop hooks of velcro plates fastened to the vehicle floor, so that a secure attachment of the doormat in the motor vehicle. In the case of subsequently in the vehicle floor to be attached fasteners, z. B. Velcro plates, mark the provided in the lower layer velor surfaces of the adapted geometry for the customer exactly the positions where the climber mounted in the vehicle, z. B. screwed into the floor covering Need to become. To a particularly firm connection of the upper class to reach with the lower class, it is suggested that the both layers additionally melted or melted Shares of a polyethylene powder solidified and bonded together are. In the manufacturing process, this is done before the introduction the layers in the press a polyethylene powder on the at Joining facing sides of the topsheet and the backsheet applied and solidified. In the thermal treatment of the layers Then, in addition to the PE components of the layers, the PE powder will also be used melted, resulting in an additional connection between leads the layers. By using a sufficient Quantity of PE powder per unit area leaves In addition, a waterproofing reach the doormat. With a water-impermeable Doormat is located under the doormat Vehicle floor against contamination by spilled liquids or rain or melt water protected.

When Material for the upper layer may be a tufting of polyamide fibers Use find that has a polypropylene back. In the thermal treatment of the layers then takes a solid Combination of the melt fibers of the lower layer or of the polyethylene powder with the polypropylene back of the upper layer, since both materials belong to the group of polyolefins.

Besides However, it is proposed that the upper class in accordance with the lower layer of a mixture of polypropylene fibers and Polyethylene fibers consists. This results in a varietal textile doormat with excellent properties, at 100% recycling is guaranteed.

Around the mechanical properties of the bottom of the doormat still to be strengthened, it is proposed that the Undercoat a latex SBR (styrene butadiene rubber) impregnation or Pflatschung receives, wherein the compound of upper layer and underlayer the patted / impregnated side of the Bottom layer to the top shows.

A Further increase in slip resistance can be achieved by the targeted Choice of the arrangement of the direction of the velor of the lower layer be achieved. The direction of the velor of the vehicle floor usually always runs in the direction of travel. Likewise, the velor of the upper layer of the doormat should run in the direction of travel when used in the motor vehicle. This serves optical aspects by removing unwanted streaks by the movement of the feet on the vehicle floor or the doormat to be avoided. Will the direction of the Suede of the lower layer when using the doormat in the motor vehicle against the direction of the velor of the vehicle floor chosen, there is an additional wedging the fibers of the doormat in the fibers of the vehicle floor.

in the Frame of the manufacturing process can also be a bordering of the flooring done in a conventional manner.

example 1

First of all, needled nonwovens made of a mixture of polypropylene (PP) fibers and polyethylene (PE) fibers were produced as the upper layer and lower layer, as described in US Pat DE 297 06 968 U1 is described. For the topsheet and the backsheet, a blend of 50% to 97% PP fibers with 3% to 50% PE melt fibers, type ASOTA H10 LLDPE / HDPE was used. Upper layer and lower layer were first punched out in the appropriate shape of the doormat to be produced. For a firm connection of the two layers was a PE powder having a melting temperature of 110 ° C to 130 ° C, a grain size of 0 to 400 microns and a wash resistance at 90 ° C on the facing sides of the upper layer and the lower layer applied and solidified. The combination of the two layers and simultaneous thermal embossing of the lower layer was carried out on an APV plant with a temperature of 158 ° C at 25 seconds residence time and a pressure of 6 bar.

Example 2

at another doormat was made as in Example 1. For the needle felt of the upper class was again a blend of 50% to 97% PP fibers with 3% to 50% PE melt fibers, Type ASOTA H10 LLDPE / HDPE, used. In the needle felt used as a lower layer, which in turn consists of a mixture of 50% to 97% PP fibers with 3% to 50% PE melt fibers, type ASOTA H10 LLDPE / HDPE, was a latex impregnation with styrene butadiene rubber (SBR) performed. The finished doormat faced opposite Example 1 an even higher slip-resistant effect on.

Example 3

Also Here the production took place as in Example 1. As upper class however found a tufting of polyamide fibers with a polypropylene (PP) -back and as underlayer a needle felt as in Example 1 Use.

In the drawing, the invention is explained in detail. Show it:

1 to 8th Views of the bottoms of doormats and

9 a section along the line IX-IX of 8th ,

The 1 to 4 show views of the undersides of floor mats according to the invention 1 , which have a suitable pattern in the manner of a tire profile by thermal embossing of the lower layer in the production for improving the slip resistance. As can be seen clearly, the running direction of the tire profile is formed transversely to the running direction of the suede of the lower layer.

During the thermal embossing are the areas 2 pressed and the completely black drawn areas 3 sublime trained. This results in a pattern on the bottom of the doormat, which ensures safe slip resistance when using the doormat in a motor vehicle by the raised areas 3 of the pattern in the velor of the vehicle floor.

The floor mats 1 are with a mount 4 provided, which can be sewn, for example.

The 5 to 8th again show views of the undersides of floor mats 1 however, they are equipped with a pattern formed by simple geometrical shapes.

At the doormat 1 of the 5 stand by the thermal embossing of the lower layer of the pressed area 2 sublime areas 5 out. The arrangement of the raised areas 5 is chosen so that when using the doormat 1 gives a safe slip resistance in a motor vehicle.

additionally can here, as with all other figures, for one additional safety against slipping the direction of travel the velor be arranged so that they are in use in a motor vehicle against the direction of the velor of the vehicle floor lies.

Also the floor mats 1 of the 5 to 8th are with a mount 4 Mistake.

The floor mats 1 of the 6 and 7 have other patterns made of simple geometric figures on the underside. at 6 protrude from the area pressed by the thermal imprint area 2 angular raised areas 6 and circular raised areas 7 out.

The underside of the doormat 1 of the 7 is in contrast with arcuate raised areas 8th from the pressed area 2 fitted. Again, you can see the formation of the pattern across the direction of the velor bottom.

In the 8th is essentially the doormat 1 of the 5 shown. In contrast to 5 points the bottom next to the raised areas 5 for anti-slip two further, for example circular areas 9 from in the context of thermal embossing unmodified velor on. The geometry of the areas 9 is particularly adapted to the connection of the doormat 1 with fasteners, especially Velcro fasteners, on the vehicle floor, as this is particularly evident in connection with the 9 results.

The 9 shows a schematic section along the line IX-IX of 8th in conjunction with a schematic representation of a vehicle floor 10 which consists of a velor carpet fixed in the vehicle.

For secure attachment of the doormat 1 on the vehicle floor 10 is a fastening system in the form of Velcro plates 11 provided with not shown Velcro hooks. The velcro plates 11 are doing with a attached to them and only schematically indicated screw 12 in the vehicle floor 10 screwed. Alternatively, the velcro plates could 11 also with the vehicle floor 10 glued or otherwise connected.

The arrangement of the circular areas 9 and the velcro plate 11 is chosen so that this when using the doormat 1 come to rest on each other, so that the Velcro hooks in the velor of the circular areas 9 intervene and the doormat 1 on the vehicle floor 10 Fasten.

The direction of the velor of the vehicle floor 10 runs in the direction of the arrow 13 whereas the running direction of the velor is the lower layer of the doormat 1 against the direction of the arrow 13 is selected. This results in addition to the wedging of the raised areas 5 in the velor of the vehicle floor 10 an additional wedging of the velvet of the doormat 1 in the velor of the vehicle floor 10 , Overall, the doormat is 1 thus secured in a threefold manner against slipping in the vehicle. The direction of the velor of the upper layer of the doormat 1 is usually turn in the direction of the arrow 13 aligned.

Due to the special design of the circular areas 9 Make these for the user when installing the velcro plates 11 in the vehicle floor 10 Markings on the bottom of the doormat 1 represents the exact installation position for the velcro plates 11 and ensure correct installation.

It is understood that over the illustrated in the drawing Pattern out further designs are conceivable without the frame to leave the invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 29706968 U1 [0003, 0004, 0023]
• - DE 19812925 A1 [0004]
• - DE 10336459 A1 [0005]

Claims (24)

Doormat ( 1 ) for motor vehicles with slip-resistant underside with a) a needle-punched nonwoven as a topsheet, which consists of thermoplastic fibers, and b) a needle-punched nonwoven fabric as a lower layer, which consists of a mixture of polypropylene fibers and polyethylene fibers; or from biconstituent fibers consisting of a blend of polypropylene and polyethylene; or a mixture of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers, c) wherein the two layers are solidified and joined together by molten or fused fibers consisting of the polyethylene portion of the two layers; and d) the Underlayer is thermoformed to improve slip resistance. Doormat ( 1 ) according to claim 1, characterized in that the improvement of the slip resistance by the formation of a suitable pattern, preferably transversely to the direction of the velor of the lower layer is reached. Doormat ( 1 ) according to claim 2, characterized in that the pattern is formed by simple geometric shapes. Doormat ( 1 ) according to claim 2, characterized in that the pattern is formed in the manner of a tire profile. Doormat ( 1 ) according to one of the preceding claims, characterized in that the lower layer has an adapted geometry for connecting the doormat with fasteners, in particular Velcro fasteners, on the vehicle floor. Doormat ( 1 ) according to one of the preceding claims, characterized in that the two layers are additionally solidified and joined together by molten or melted portions of a polyethylene powder. Doormat ( 1 ) according to one of claims 1 to 6, characterized in that the top layer consists of polyamide fibers and has a polypropylene back. Doormat ( 1 ) according to one of claims 1 to 6, characterized in that the top layer consists of a mixture of polypropylene fibers and polyethylene fibers. Doormat ( 1 ) according to one of the preceding claims, characterized in that the lower layer has a latex SBR (styrene butadiene rubber) impregnation or Pflatschung, wherein in the combination of upper layer and lower layer, the padded / impregnated side of the lower layer to the upper side. Doormat ( 1 ) according to one of the preceding claims, characterized in that the running direction of the suede of the lower layer when using the doormat ( 1 ) in the motor vehicle against the direction ( 13 ) of the vehicle floor ( 10 ) lies. Doormat ( 1 ) according to one of the preceding claims, characterized in that the doormat ( 1 ) with a border ( 4 ) is provided. Method for producing a doormat ( 1 ) for motor vehicles with slip-resistant underside, wherein a) a needle-punched nonwoven fabric as a topsheet, which consists of thermoplastic fibers, with a needle-punched non-woven fabric as the lower layer, which consists of a mixture of polypropylene fibers and polyethylene fibers; or from biconstituent fibers consisting of a blend of polypropylene and polyethylene; or a mixture of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers, are joined together in a press by thermal treatment in the press, the polyethylene portions melting, and then b) a thermal embossing of the underlayer to improve slip resistance. Method for producing a doormat ( 1 ) for motor vehicles with slip-resistant underside, in which a needle-punched nonwoven as a top layer, which consists of thermoplastic fibers, with a needle-punched nonwoven as an underlayer, consisting of a mixture of polypropylene fibers and polyethylene fibers; or from biconstituent fibers consisting of a blend of polypropylene and polyethylene; or a mixture of these biconstituent fibers and polypropylene fibers and / or polyethylene fibers, are joined together in a press by a thermal treatment is performed in the press, wherein the polyethylene portions melt and at the same time a thermal embossing of the underlayer to improve the Slip safety occurs. Method according to claim 12 or 13, characterized characterized in that during the thermal embossing the lower layer improving the slip resistance through the Forming a suitable pattern, preferably transversely to the direction of the Suede of the lower class, done. Method according to claim 14, characterized in that that the pattern is formed by simple geometric shapes. Method according to claim 14, characterized in that that the pattern is formed in the manner of a tire profile. Method according to one of claims 12 to 16, characterized in that during the thermal embossing of the lower layer of an adapted geometry for connecting the doormat ( 1 ) with fasteners, in particular Velcro fasteners, on the vehicle floor ( 10 ) is formed. Method according to one of claims 12 to 17, characterized in that prior to the introduction of the layers in the press a polyethylene powder on when joining each other facing sides of the upper layer and the lower layer applied and solidified. Method according to one of claims 12 to 18, characterized in that the upper layer of polyamide fibers exists and has a polypropylene back. Method according to one of claims 12 to 18, characterized in that the upper layer of a mixture made of polypropylene fibers and polyethylene fibers. Method according to one of claims 12 to 20, characterized in that the underlayer is a latex SBR (styrene Butadiene rubber) impregnation or patting, wherein the compound of upper layer and lower layer, the potted / impregnated Side of the lower layer to the top shows. Method according to one of claims 12 to 21, characterized in that the running direction of the suede of the lower layer when using the doormat ( 1 ) in the motor vehicle against the direction ( 13 ) of the vehicle floor ( 10 ) lies. Method according to one of claims 12 to 22, characterized in that the doormat ( 1 ) with a border ( 4 ). Doormat ( 1 ) for motor vehicles with slip-resistant underside, produced by a method according to one of claims 12 to 23.