DE3510722A1 - VEHICLE FLOOR PAD - Google Patents

Description

se p + G-367

Schaeffler Carpeting GmbH, 86OO Bamberg Vehicle floor support

The invention relates to a vehicle floor covering consisting of a carpet and a foam soundproofing mat, that is connected to the underside of the carpet and that at least on the one facing the carpet Side has a closed skin.

Such automobile floor coverings are known. The carpet, especially the pile carpet, makes up the interior of the Vehicle comfortably. The sound insulation mat mostly consists of a polyurethane foam. You diminished the sound transmission from the floor pan into the interior. The sound insulation mat has ribs and webs on its underside or similar formations of the vehicle sheet metal. On its upper side facing the carpet it is in essentially flat and has a closed skin. The skin is not formed by a separate film,

it is created when the sound insulation mat is foamed in a form. Through the skin is the top the sound insulation mat water-repellent, so that water penetrates through the carpet to the sound insulation mat cannot penetrate into this. Forcing water or moisture into the soundproofing mat, it would this is stored there, which would be very uncomfortable because, on the one hand, the water absorption capacity of the sound insulation matt is large and, on the other hand, the possibilities for drying out are poor.

In the case of the known automobile floor coverings, the carpet is attached by means of a solvent-based adhesive firmly connected to the sound insulation mat. When the adhesive hardens, solvent vapors are released into the environment. This is undesirable. To achieve a sufficient bond, about 200 p / m are necessary. As part of the This weight is not negligible in the weight reduction aimed at in the automotive industry. The glue forms only an adhesive connection between the undersides of the poles and the skin. It cannot be ruled out that he dissolves over time when exposed to heat and / or moisture. Has the solvent of the glue the skin is attacked and the adhesive bond loosens, then moisture can penetrate the foam sound insulation mat. This is undesirable.

In DE-PS 1 Ο32 7i4 is a method for production of elastic laminates of continuous porosity described. There is one of each other towards one another

connecting surfaces of the layers, for example made of textiles and foams, a polymerizable, A thin layer of synthetic resin mixture that generates gases * is applied. The other layer is put on top and the layers are compressed during the evolution of gas and polymerisation of the synthetic resin mixture. To a continuous To obtain a porous product, a solvent is added to the synthetic resin mixture. Through this becomes ensures that there is no separating layer of foam, but a grid-like or net-like and therefore continuously porous connection between the two starting materials forms. This is suitable for producing a vehicle floor covering of the type mentioned at the beginning The process is not, as it should not be completely porous and the use of a solvent is undesirable is.

DE-PS 1 669 786 describes a process for the production of embossed film-like laminates. On one of the outer layers of the polyurethane foam sheet, an anhydrous film made of a foamable material is intended to be applied Polyurethane material can be applied and caused to foam by adding moisture. the Cover layers are pushed through this film and glued together so that the layers between the Make the top layers filled with foam and the top layers in these areas are connected by the foam. This is the entire space between the top layers porous. With this method, a soundproofing

Make mungsmatte of the type mentioned above, on both sides finished with foils and adapted to the profile of the floor panel. However, it can be done with the Do not produce a vehicle floor covering of the type mentioned above. Because the prefabricated Sound insulation mat should not be changed by connecting it to the carpet.

The object of the invention is, in a vehicle floor support of the type mentioned to connect the carpet with the soundproofing mat without this solvent-based adhesive is used and without this being a moisture-permeable connection between the carpet and the interior of the soundproofing mat.

The above problem is achieved with a vehicle floor support of the type mentioned in that between the carpet and the closed skin one made of a prepolymer foamed foam layer is provided and that the foam layer on the one hand the lower Zones, especially poles, of the carpet and on the other hand connected to the closed skin Has.

The prepolymer does not contain any solvent. Accordingly no solvent vapors emerge during foaming. The carpet is by means of the foam layer firmly anchored to the sound insulation mat. It is also beneficial that the foam layer is exposed to moisture

effect does not swell and does not dissolve either. The evaporation problems that exist with aqueous adhesives also arise not on.

Have the foam layer and the soundproofing mat approximately the same elasticity properties, so that there can be no tension that could damage the skin could. The foam layer reinforces or protects the closed skin, so that its watertightness is guaranteed in the long term. The connection is insensitive to the effects of moisture or heat.

When the foam layer is foamed, the skin prevents prepolymer from penetrating into the sound insulation mat. The foaming process thus takes place in the direction of the carpet, so that a very thin layer of prepolymer ensures that the carpet is reliably embedded. This also has the consequence that the weight of the foam layer is very low. It has been shown that an application of prepolymer in a weight of 30 to
permanent connection is sufficient.

a weight of 30 to 50 p / m for a safe, permanent

If the sound insulation mat consists of a polyurethane foam, then a polyurethane prepolymer is preferably used for the foam layer.

The foam layer in itself consists of closed, stable foam bubbles that adhere to one another. There are cavities between these, so that the

Foam layer itself is not water-repellent. Nevertheless, the foam layer reduces the water permeability from the carpet to the skin, because in the spaces between the bubbles of the foam layer the water-repellent Fibers of the carpet lie.

A method of joining the carpet and the Soundproofing mat of the vehicle floor covering of the entrance The type mentioned is characterized in that a prepolymer is applied to the closed skin of the sound insulation mat applied in an even layer and an activator that the carpet is pressed onto the layer while the layer is foaming.

Embodiments of the invention emerge from the following description. In the drawing show:

Figure T shows a tufted carpet vehicle floor covering schematically in section and

FIG. 2 shows a needle punched carpet vehicle floor covering schematically in section.

The vehicle floor covering has a polyurethane foam -Sound insulation mat 1 on. This is on its underside according to the contour of a vehicle floor panel profiled and covered with a waterproof film 2. On its upper side, the mat 1 is essentially

lichen even and closed with a waterproof skin 3. The skin 3 is created during the production of the sound insulation mat 1. It breaks open easily when scratched. It is much more sensitive than slide 2. After If the skin 3 is broken open, moisture can enter the interior of the mat 1.

The vehicle floor covering according to FIG. 1 has a tufted carpet 4, whose loops 5 in the usual way to a Carrier grid 6 are fixed. There are the poles of the carpet. The carpet is made of fibers, for example made of polyamide, polyester, polyacrylic or polypropylene.

A polyurethane foam layer is bonded to the skin 3 without glue. The foam layer 7 extends over the carrier grid 6 and thus encloses the poles of the carpet 4. It fills trees between the loops 5. As a result, the loops 5 are mechanically anchored in the foam layer 7.

The foam layer 7 has approximately the same elasticity as the sound insulation mat 1. When the carpet k is treaded, it takes along the deformation of the sound insulation mat 1 without tearing. The foam layer 7 is intimately connected to the skin 3. In the process, it strengthens the skin 3 ″ At the same time, it protects the skin 3 from mechanical damage acting through the carpet k.

The foam layer 7 consists of closed

Foam bubbles, so that their water absorption capacity is low is. The water absorption capacity is further reduced by the fact that the voids between the vesicles are largely are occupied by the loops 5. Will the carpeting If soaked, then the foam layer 7 will hardly absorb water. Above all, however, no water is in penetrate the sound insulation mat 1. The dehydration possibilities are good because of that. The dehydration is usually caused by that prevailing in the vehicle interior Air flow. Under no circumstances is it necessary to remove the floor covering that is permanently installed in the vehicle after it has been wetted to remove and dry out. Even with prolonged use, these properties do not change because the Foam layer 7 itself is insensitive to the effects of moisture and is insensitive to the temperatures occurring in the motor vehicle. Come in addition, that the foam layer 7 to be taken into account Stress does not tear, so that the skin 3 cannot crack either. That in the foam layer 7 embedded support grid 6 forms an additional reinforcement of the foam layer 7.

In practice, the carpet k has a thickness of approximately 0.5 to 1 cm. The soundproofing mat 1 is thicker than the carpet, at least in the area of its greater thickness. Its thickness varies, for example, between 1 and 3 cm. In practice, the foam layer 7 has a thickness of approximately 0.2 mm to 1.5 mm.

The vehicle floor support described is approximately in the following Way made;

A liquid polyurethane prepolymer is applied to the skin 3 of the prefabricated sound insulation mat 1. This application can take place, for example, by spraying. The application rate is 30 to 50 p / m. An activator is then applied, which initiates the foaming process. A corresponding piece of carpet k is then immediately placed on the prepolymer and pressed into a mold. The prepolymer now foams - if necessary under the action of heat. During foaming, the prepolymer presses against the skin 3 on the one hand. The resulting foam bubbles connect to the skin 3 without penetrating the skin 3. Since the foam bubbles do not penetrate the skin 3, there will be a more dense distribution of bubbles in the immediate vicinity of the skin 3 than in areas further away from the skin. On the other hand, the polyurethane foam layer 7 penetrates into the irregularities of the carpet backing and fills them out. The bubbles formed during foaming pass through the carrier grid 6 and into the loops 5 or their spaces. After the foaming process, the carpet k is finally firmly connected to the sound insulation mat 1. The skin 3 is reinforced by the concentration of the bubbles in the foam layer 7 there. The poles of the carpet k are anchored in the foam layer 7. The proportion of the weight of the foam layer 7 in the total weight of the vehicle floor covering is negligible »

In the embodiment according to FIG. 2, a needle punched carpet is provided instead of the tufted carpet.

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What is described in relation to FIG. 1 also applies here. It could be In the same way, also permanently connect a woven carpet to the soundproofing mat 1.

It has been shown that a secure carpet connection is also achieved when the sound insulation mat 1 is made of a polyethylene foam, the one closed has sene skin 3 and is difficult to glue.

Should the vehicle floor support not be flat, but rather spatially deformed to adapt to the vehicle interior then, in the connection described, a suitably pre-formed soundproofing mat is used and from an appropriately preformed piece of carpet went out.

Claims (7)

Expectations 1. Vehicle floor covering consisting of a carpet and a foam sound insulation mat which is connected to the underside of the carpet and which has a closed skin at least on the side facing the carpet, characterized in that between the carpet (k) and the closed skin (3) a foam layer (7) foamed from a prepolymer is provided and that the foam layer (7 ) encloses the lower zones (6) of the carpet (k) and, on the other hand, is connected to the closed skin (3). 2. Vehicle floor support according to claim 1 with a pile carpet, characterized in that the poles in the Foam layers (7) are anchored. 3. Vehicle floor support according to claim 1 or 2, with a polyurethane or polyethylene foam soundproofing mat e, characterized in that the foam layer (7) is foamed from a polyurethane prepolymer. k, vehicle floor support according to one of the preceding claims, characterized in that the foam layer (7) consists of closed, interconnected foam bubbles. 5. Vehicle floor support according to one of the preceding claims, characterized in that the weight of the Foam layer (7) is about 30 to 50 p / m. - 12 - -VZ- 6. Vehicle floor supports according to one of the preceding Claims, characterized in that the foam layer (7) has a thickness of 0.2 now to 1.5 now. 7. Method of joining the carpet and the Soundproofing mat of the vehicle floor covering according to one of the preceding claims, characterized in that that on the closed skin of the sound insulation mat a prepolymer in an even layer and an activator and that the carpet is pressed onto the layer while the layer is foaming.