JP2002172967A - Floor carpet for vehicle and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce weight and improve sound absorption of floor carpet for a vehicle laid on a floor panel and to improve productivity by reducing time of heating process and press forming process in manufacturing. SOLUTION: An air-permeable tuft carpet 20 is manufactured by coating or laminating adhesive medium such as spray backing resin material 22, web style hot melt adhesive agent 23 or latex resin emulsion on base cloth layer 22 having pile layer 21. Simultaneous heating and simultaneous forming of the air permeable tuft carpet 20 and an air permeable cushion material 30 are enabled. Forming cycle can be reduced by suction and blow in press forming. Consequently, weight is reduced and productivity and sound absorption are improved by using the air-permeable tuft carpet 20.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor carpet for a vehicle and a method for manufacturing the same, and more particularly, to a floor carpet for a vehicle which can be reduced in weight, can improve sound absorption performance, and can shorten the manufacturing time. And its manufacturing method.

[0002]

2. Description of the Related Art Normally, a floor panel of a vehicle is provided with a structure shown in FIG.
5, a large vehicle floor carpet 1 is laid, and the vehicle floor carpet 1 is formed in accordance with the surface shape of the floor panel so as to have a tunnel 1a extending in the center along the longitudinal direction of the vehicle. Have been.

The floor carpet 1 for vehicles
26, as shown in FIG. 26, is composed of a laminate of a tuft carpet 2 and a cushion material 3 laminated and integrated on the back side thereof.

[0004] The tuft carpet 2 comprises a pile layer 4,
It is composed of a three-layer structure of a base cloth layer 5 and a backing layer 6,
The pile layer 4 is made of PP, nylon (polyamide resin), P
Synthetic fibers such as ET (polyester) are used, the base fabric layer 5 is a base for implanting each fiber of the pile layer 4, the backing layer 6 is a polyethylene resin sheet, and the sealing function of the pile layer 4 is provided. And a function of bonding the cushion material 3 to the cushion material 3.

By the way, the method of manufacturing the tufted carpet 2 is as shown in the process chart of FIG.
The pile yarns are implanted into the base fabric layer 5 by tufting operation, subjected to a repairing process and a greige process, laminated with a backing layer 6 of polyethylene resin or the like, and manufactured through a drying process.

In the method of manufacturing the floor carpet 1 for a vehicle, as shown in the process chart of FIG. 28, the tuft carpet 2 is heated and the cushion material 3 is formed into a required shape after the heating process. The tuft carpet 2 in the state and the preformed cushion material 3 are overlapped and molded and integrated to complete the production of the vehicle floor carpet 1 shown in FIG.

[0007]

As described above, in the conventional vehicle floor carpet 1, the backing layer 6 is used to enhance the sealing function of the pile layer 4 and the bonding function between the cushion material 3 and the sound insulation. The backing layer 6 generally has a surface density of 300 g / m ^2.
As described above, this is a major factor in increasing the weight of the floor carpet 1 for a vehicle, and has been a major obstacle in reducing the weight.

The heavy floor carpet 1 for a vehicle has the drawbacks that fuel efficiency is reduced and workability at the time of mounting work to a vehicle body panel is deteriorated.

Further, since the backing layer 6 is formed over the entire back surface of the base fabric layer 5, the tuft carpet 2 becomes impermeable due to the backing layer 6, so that room noise does not reach the cushion material 3. This is a factor that impairs sound absorption performance.

Next, a conventional vehicle floor carpet 1 will be described.
It is necessary to heat the tuft carpet 2 and the cushion material 3 separately, and at least two heating steps are required, which not only increases the number of steps but also increases the size of the equipment and causes the heating. When the tufted carpet 2 is formed, since the backing layer 6 interposed between the pile layer 4 and the cushion material 3 has heat insulating properties, it takes time to cool the backing layer 6 (about 30 to 30).
(90 seconds) It is pointed out that the molding cycle is prolonged and the productivity is reduced.

The present invention has been made in view of such circumstances, and has been made to reduce the weight of a floor carpet for a vehicle.
Further, it is an object of the present invention to provide a floor carpet for a vehicle and a method for manufacturing the same, which can enhance the sound absorbing performance, enable simultaneous heating of the tuft carpet and the cushioning material, and reduce the number of steps and the molding time. And

[0012]

In order to achieve the above object, a vehicle floor carpet according to claim 1 of the present application is provided with a tufted carpet having air permeability formed according to the shape of a floor panel. And a cushioning material laminated and integrated on the back surface of the tufted carpet.

Further, according to the invention described in claim 2 of the present application, the tufted carpet has a pile layer on a carpet surface, a base fabric layer for planting the pile layer, a filling function of the pile layer, and a cushion material. In order to ensure the adhesiveness between them, the backing layer is made of a resin material formed by a spray backing process on the back surface.

Here, the pile layer of the tufted carpet is
High melting point fibers such as nylon (polyamide resin) fibers and PET (polyester) fibers are desirable, and fibers having a melting point at least 40 to 50 ° C. higher than the softening point of the resin material by spray backing are preferable. The base fabric layer is for implanting a pile layer, and a general-purpose fabric is used.

On the other hand, the resin material formed on the base fabric layer by spray backing imparts adhesion between the filling function of the pile layer and the cushion material, and is made of PE resin, polyisobutylene resin, polyamide resin, acetate resin, or the like. A vinyl-ethylene copolymer can be used, and the basis weight is 10 to 250 g / m ^2.
The spray-backed tuft carpet has air permeability.

According to a third aspect of the present invention, in the tuft carpet, a pile layer on a carpet surface, a base fabric layer for planting the pile layer, a filling function of the pile layer, and a cushion material are provided. It is characterized by comprising a web-like hot-melt adhesive laminated on the back surface of the base fabric layer in order to ensure adhesiveness.

[0017] Here, the basis weight of the web-like hot melt adhesive is 10 to 250 g / ^{m 2,} missing pile is less than 10 g / ^{m 2,} peeling or the like occurs, if it exceeds 250 g / ^{m 2} in the opposite Has almost no air permeability and cannot expect a sound absorbing effect.

The material of the hot melt adhesive is preferably a polyolefin or polyester hot melt adhesive having a melting point at least 40 to 50 ° C. lower than the softening temperature of the high melting point fiber such as nylon fiber or polyester fiber. .

According to a fourth aspect of the present invention, in the tufted carpet, a pile layer on a carpet surface, a base fabric layer for planting the pile layer, a filling function of the pile layer, and a cushion material are provided. It is characterized by comprising a latex / resin emulsion applied to the back surface of the base fabric layer in order to ensure adhesiveness.

When a latex / resin emulsion is used, the basis weight of the latex or the like is 20 to 500.
g / m ² . If the amount is less than 20 g / m ² , the pile will be missed, and if it exceeds 500 g / m ² , it will be difficult to form and develop. The tuft carpet material after the latex treatment is covered with the resin particles, so that the gas permeability can be obtained.

According to a fifth aspect of the present invention, in the tuft carpet, the pile layer on the surface of the carpet, a nonwoven fabric having a pseudo backing function for planting the pile layer, and a nonwoven fabric laminated on the nonwoven fabric, It is characterized by comprising a powder-like, film-like, or web-like adhesive medium for securing the adhesiveness between the stopper function and the cushion material.

Here, when the base fabric layer is a pseudo backing layer such as a polyester non-woven fabric, the basis weight of the pseudo backing layer is 100 to 800 g / m ² and the basis weight is 100 g / m ^2.
If it is less than m ² , it will cause a decrease in product strength and formability, and if the basis weight exceeds 800 g / m ² , it will result in poor pile planting property, poor moldability, increase in product weight and decrease in air permeability. Further, the basis weight of the film-like or web-like hot melt or resin powder previously laminated on the pseudo backing layer is 10 to 250 g / m ² .

In the floor carpet for a vehicle according to any one of claims 1 to 5, the backing layer is spray-backed with a resin material, a hot-melt adhesive is laminated, or a latex resin emulsion is applied. In place of the conventional non-breathable sheet-like backing layer, pile sealing and bonding with the cushioning material can be made possible with air permeability secured. The weight can be significantly reduced.

Further, since there is no sheet-like resin backing layer serving as a sound insulating material, the noise in the room reaches the cushion material, and the sound absorbing performance in the vehicle cabin can be improved.

Next, the invention according to claim 6 of the present application is directed to a method of manufacturing a floor carpet for a vehicle, wherein a cushion member is laminated and integrated on the back surface of the tufted carpet and is formed according to the surface shape of the floor panel. On the back side of the tuft carpet, an adhesive medium such as a resin material or a hot melt adhesive is spray-coated or laminated, and the tuft carpet is provided with air permeability, or air permeability is provided by supplying hot air, and the tuft carpet is After being overlapped with the cushion material and subjected to an integral heat treatment, it is formed into a required shape by integral press molding.

Here, the spray backing treatment of the resin material is performed by applying a melted PE resin or the like to the base fabric layer in a spray form, then pressing the base material with a roller or the like, and then entering a powder dropping process, or a tufted base material. There is a method in which a resin powder such as polyethylene is sprayed on the back surface of the cloth layer, the polyethylene resin is melted by an infrared heater or the like, and then pressure-bonded by a roller or the like, and then a powder removing step is performed.

Further, a web-like hot melt adhesive may be applied to the back surface of the base fabric layer by a heat laminating step, and a latex / resin emulsion may be applied.

According to the sixth aspect of the present invention,
Since the tuft carpet has air permeability, the hot air heating treatment can be performed simultaneously with the cushion material, and the heating time can be reduced.

According to a seventh aspect of the present invention, in the integrated press forming step of the tuft carpet and the cushion material, heat in the forming die is removed to the outside by suction force, or cooling air is formed in the forming die. It is characterized in that the molding cycle is shortened by supplying it to the inside.

According to the seventh aspect of the present invention,
Since the tuft carpet has air permeability, warm air in the mold can be exhausted to the outside of the mold during integral press molding of the tuft carpet and the cushioning material, and cooling air is supplied from outside to the mold. For example, by adding suction or blow molding, the molding time can be shortened.

The invention according to claim 8 of the present application provides a method of manufacturing a floor carpet for a vehicle in which a cushioning material is laminated and integrated on the back surface of a tufted carpet and is molded according to the surface shape of the floor panel. The present invention is characterized in that a tuft carpet having a property and a cushion material are simultaneously press-molded.

According to the eighth aspect of the present invention,
This is to integrally mold a non-molded type cushion material such as cure felt and a tufted carpet having air permeability, and it can be applied to a non-molded cushion material such as cure felt and polyester fiber.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a floor carpet for a vehicle in which a cushion material is laminated and integrated on the back surface of a tufted carpet and is formed according to the surface shape of a floor panel. After forming a tufted carpet having properties into a required shape, a cushion material is attached to the back surface of the tufted carpet with an adhesive.

According to the ninth aspect of the present invention,
After the tuft carpet is formed into a required shape, it can be applied to a non-molded type cushion material such as chip urethane or slab urethane using an adhesive or the like.

According to a tenth aspect of the present invention, there is provided a method for manufacturing a floor carpet for a vehicle, wherein a cushioning material is laminated and integrated on the back surface of the tufted carpet and is formed according to the surface shape of the floor panel. After spraying a web-like hot melt, resin powder, etc. on the back of the tufted carpet having properties, the material of the cushioning material is laminated in a fleece shape on it, and the tufted carpet and the cushioning material are integrated by heat treatment. It is characterized by being pressed into a shape.

According to the tenth aspect of the present invention, a resin powder is sprayed on the back surface of the ventilation type tuft carpet, or a hot melt adhesive is applied or laminated, and a felt nonwoven fabric or the like is formed thereon. The raw cotton may be laminated, integrated with the cushioning material by heating, and then heat-softened and then press-formed. When the cushioning material is manufactured and combined with the ventilated tufted carpet, the adhesive strength with the cushioning material can be improved.

An eleventh aspect of the present invention is characterized in that a resin material or an adhesive medium such as a hot melt adhesive is sprayed or laminated before and after the greige step of the tufted carpet.

According to the eleventh aspect of the present invention, at the time of manufacturing the tufted carpet, after the tufting is performed on the base fabric layer on which the spray backing or the hot melt adhesive is laminated in advance, the repair, the greige process is further performed. Thereafter, by performing spray backing or laminating and applying a hot-melt adhesive, the pile-pulling strength can be further increased.

The invention according to claim 12 of this application is a method of manufacturing a floor carpet for a vehicle, wherein a cushioning material is laminated and integrated on the back surface of the tufted carpet and is formed according to the surface shape of the floor panel. After fabricating the tuft carpet by implanting the pile layer in the base fabric, spray or apply an adhesive medium such as a resin powder or a hot melt adhesive on the back of the tuft carpet, set a cushion material thereon, and simultaneously heat, It is manufactured by simultaneous press molding.

According to the twelfth aspect of the present invention, a resin powder is sprayed on the back surface of the tuft carpet during the production of the floor carpet, or a film-like hot melt adhesive is laminated and applied. When the powder is sprayed, the powder removing step can be reduced, and the material efficiency can be increased by eliminating the powder lost in the powder removing step.

When a web-like hot-melt adhesive is used, since the cushioning material has a high heat-retaining effect, the degree of dissolution of the hot-melt adhesive increases, and the pile-pulling strength and adhesive strength increase.

[0042]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a floor carpet for a vehicle and a method of manufacturing the same according to the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is a sectional view showing the structure of a floor carpet for a vehicle according to the present invention, and FIGS.
FIG. 2 is a schematic cross-sectional view of a tuft carpet, FIG. 3 is a schematic plan view of the tuft carpet viewed from the back side, FIG. 4 is a process chart illustrating a method for manufacturing the tuft carpet, and FIG. FIGS. 6 to 8 are process charts showing a method of manufacturing a floor carpet for a vehicle, and FIGS.
FIG. 9 is a process chart showing a modification of the method of manufacturing a tuft carpet, and FIGS. 10 and 11 are process charts showing a modification of the method of manufacturing a floor carpet for a vehicle.

Next, FIGS. 12 to 16 show a second embodiment of the present invention.
FIG. 12 and FIG. 13 are schematic cross-sectional views of a tufted carpet, a schematic plan view seen from the back side, and FIG.
FIG. 1 is a process chart of a tuft carpet manufacturing method, and FIG.
5 is a process chart illustrating a modification of the method for manufacturing a tuft carpet, and FIG. 16 is a process chart illustrating a modification of the method for manufacturing a floor carpet for a vehicle.

FIGS. 17 to 20 show the third embodiment of the present invention.
FIG. 17 and FIG. 18 are schematic cross-sectional views of a tufted carpet, a schematic plan view viewed from the back side, and FIG.
9 and FIG. 20 are process charts showing a method of manufacturing a tufted carpet.

FIGS. 21 to 24 show a fourth embodiment of the present invention. FIGS. 21 and 22 are schematic cross-sectional views of a tufted carpet, and schematic plan views as viewed from the back.
FIG. 23 and FIG. 24 are process charts showing a method for manufacturing a tufted carpet.

In FIG. 1, a floor carpet 1 for a vehicle is shown.
0 is the tuft carpet 20 located on the product surface side,
And a cushion material 30 laminated and integrated on the back side. The cushion material 30 is made of a material having air permeability, blended with a thermoplastic resin / thermoplastic fiber, and capable of being cold pressed.

The tuft carpet 20 in the vehicle floor carpet 10 according to the present invention has a lightweight and air-permeable bonding means by eliminating the conventional sheet-like and heavy resin backing layer. The feature is that there is.

Next, each embodiment will be described.
First, FIG. 2 to FIG. 11 show a first embodiment of the present invention.
The tuft carpet 20 used in the first embodiment is:
As shown in FIGS. 2 and 3, the pile layer 21, the base fabric layer 22,
And a resin material 23 that is randomly spray-backed on the back surface of the base fabric layer 22.

The pile layer 21 is made of a high melting point fiber such as nylon (polyamide resin) fiber or PET (polyester) fiber, and the pile layer 21 is implanted in the base fabric layer 22.

The resin material 23 spray-backed on the back surface of the base fabric layer 22 is made of PE (polyethylene).
A resin or a hot melt resin such as polyisobutylene, polyamide, vinyl acetate-ethylene copolymer or the like is used, and the basis weight of the resin material 23 is 10 to 250 g /
It is adjusted to a range of m ^2. Note that the melting point of the resin material 23 is 40
A low-melting point resin material having a temperature lower by 50 ° C. or more is used.

Next, in the method of manufacturing the tufted carpet 20, as shown in FIG. 4, a pile yarn is implanted in a base cloth to perform a tufting process, and after a repairing process and a greige process, a backing process is performed on the resin material 23. The tuft carpet 20 is manufactured through a powder removing step.

At this time, in the spray backing step,
Spray the melted PE resin onto the base fabric and then press it with a roller, etc., and start the powder removal process, or spray the PE resin on the back of the tufted base fabric and melt the PE resin with an infrared heater etc. After that, the polyethylene may be pressure-bonded by a roller or the like, and thereafter, the process may be started in a powder removing step.

As described above, the tuft carpet 20 in the first embodiment eliminates the conventional sheet-like and heavy bulky backing layer, and randomly applies the resin material 23 to the back surface of the base fabric layer 22 by spray backing. The random resin material 23 provides a sealing function of the pile layer 21 and an adhesive property to the cushion material 30.

Therefore, compared to the conventional backing layer, the resin material 23 subjected to the spray backing treatment can be minimized and the weight of the tuft carpet 20 can be reduced, so that the fuel efficiency of the vehicle can be improved and In addition, the workability of mounting on the vehicle body panel can be improved.

In addition, since the resin material 23 does not need to be applied to the entire back surface of the base fabric layer 22, the tuft carpet 20
Of the cushion material 3
The interior noise is absorbed at zero, and the quietness of the vehicle interior can be improved.

Further, by providing the tuft carpet 20 with air permeability, the hot air heating treatment can be performed simultaneously with the cushion material 30, so that the number of steps can be reduced by one step as compared with the conventional step, and the heating time can be shortened.

In addition, when the tuft carpet 20 and the cushion material 30 are simultaneously press-molded, suction or blow molding can be added since both members have air permeability.

That is, during the cold press molding, the molding time can be shortened by forcibly exhausting (suctioning) the warm air inside the material to the outside and supplying cooling air from the outside into the mold. It becomes possible, conventional 3
The molding time spent from 0 to 60 seconds can be reduced to about 10 to 30 seconds.

As described above, in this embodiment, since the tuft carpet 20 and the cushion material 30 can be subjected to the hot air heating treatment at a time, the number of steps can be reduced, the heating equipment can be simplified, and suction or blow molding can be performed. Can be performed at the same time, the molding time can be shortened, and the productivity can be greatly increased.

Next, FIG. 6 is a process chart showing a method of manufacturing a floor carpet 10 for a vehicle manufactured using a non-molded type cushion material 30 such as a cured felt or a polyester fiber body and the tufted carpet 20 according to the present invention. When the non-molded type cushion material 30 is used, it can be easily applied simply by simultaneously molding both as shown in FIG.

As shown in FIG. 7, a non-molded type cushion material 3 such as chip urethane or slab urethane is used.
Regarding 0, the floor carpet 10 for a vehicle can be manufactured simply and at low cost by forming the tuft carpet 20 and then attaching the cushion material 30 to the back surface with an adhesive.

FIG. 8 omits the step of forming the cushion material 30 into a sheet. As shown in FIG. 8, a web-like hot melt or resin powder is applied to the back of the tuft carpet 20 shown in FIGS. And raw cotton such as felt or nonwoven fabric serving as a cushioning material is laminated thereon, and integrated with the cushioning material 30 by heating. Thereafter, the material is heated and softened and then press-molded to produce the floor carpet 10 for a vehicle. When the cushion material 30 is manufactured, the material is combined with the ventilated tuft carpet 20 to increase the adhesive strength with the cushion material 30. Can be strong.

Next, FIG. 9 shows an improvement of the tuft carpet 20 in the first embodiment. The tufting is performed on a base fabric layer which has been subjected to spray backing in advance, and a pile thread is sewn. Then, for the purpose of improving the pile pull-out strength, further spray backing or laminating a hot melt adhesive in the form of a web is performed.If the spray backing is performed twice, the spray backing is applied to the base cloth. The amount to be performed is 10 to 150 g / m ^2, and the application amount after the greige step is 10 to 150 g / m ² .

By performing the spray backing process or the laminating process of the web-like hot melt before and after the greige process, a stable pile pulling strength can be secured.

As a method of manufacturing a floor carpet for a vehicle, as shown in FIG. 10, the tuft carpet 20 and the cushion material 30 can be temporarily assembled or laminated simultaneously with heating. And the pile thread removal strength can be enhanced.

Further, as shown in FIG. 11, the tufted carpet material is fed to the greige process, and thereafter, when manufacturing the floor carpet for a vehicle, a resin powder is sprayed on the back surface of the tufted carpet, and the cushion material 30 is set thereon. Heat molding can also be performed.

In this manufacturing method, no resin powder is used in the tuft carpet manufacturing process, so that the powder removing process can be reduced, and the powder that is lost in the powder removing process can be eliminated, thereby achieving effective use of materials and cost reduction. it can.

Next, a second embodiment of the present invention will be described with reference to FIGS. In the second embodiment, a tuft carpet 20 shown in FIGS. 12 and 13 is used.

That is, the tufted carpet 20 has a pile layer 21, a base cloth layer 22 in which the pile layer 21 is implanted, a filling function of the pile layer 21, and a back surface of the base cloth layer 22 so as to provide an adhesive property to the cushion material 30. And a web-like hot-melt adhesive 24 laminated on the substrate. The basis weight of the web-like hot-melt adhesive 24 is 1
0~250g / ^{m 2,} easily removed or peeling or the like occurs pile is less than ^{10g / m 2, 250g / m} 2 in the opposite
When it exceeds 2,000, the air permeability is almost lost, and no sound absorbing effect can be expected.

Further, the material of the web-like hot melt adhesive 24 is a polyolefin-based or polyester-based hot melt adhesive, which is 40 to 5 times higher than the high melting point fiber such as nylon fiber or polyester fiber used as the pile layer 21.
Those having a melting point of 0 ° C. or higher are preferred.

Then, the above-mentioned tuft carpet 20
As shown in FIG. 14, after the pile yarn is tufted to the base cloth, the repair process and the greige process are performed, the web-like hot melt adhesive 24 is thermally laminated, and the drying process is performed. 12, the tufted carpet 2 shown in FIG.
0 can be produced.

As described above, since the tufted carpet 20 of the second embodiment is lightweight and of a ventilation type,
As in the embodiment, since the weight can be reduced as compared with the conventional heavy sheet-like backing layer, the work of attaching the vehicle floor carpet 10 to the vehicle body panel can be easily performed, and the fuel efficiency can be improved.

Further, since the cushioning material 30 does not block the noise in the vehicle interior by the backing layer, the cushioning material 30 has a structural advantage that the sound absorbing performance in the vehicle interior can be enhanced, and the cushioning material 30 is air-permeable. Since the hot air heating process can be performed integrally with the heating device 30, the heating process can be shortened in the method of manufacturing the vehicle floor carpet 10 as in the first embodiment, and the productivity can be improved by shortening the molding press time. be able to.

Further, a non-molded type cushion material 30 may be applied to the tuft carpet 20 in the second embodiment, or the tuft carpet 20 may be used when the cushion material 30 is manufactured.
Can be integrated as in the first embodiment.

Next, FIG. 15 shows an improved example of the tufted carpet 20 in the second embodiment, in which a web-like hot melt adhesive 24 is heated and laminated before and after the greige process of the tufted carpet 20. .

At this time, the basis weight of the adhesive before and after the greige process is 10 to 150 g / m ² . When the web-like hot melt adhesive 24 is thermally laminated twice, there is an advantage that a stable pile threading structure can be obtained.

Next, FIG. 16 shows another method of manufacturing the floor carpet 10 for a vehicle according to the second embodiment. In manufacturing the tuft carpet 20, the web-like hot-melt adhesive 24 is not laminated and the process up to the greige process is performed. When the floor carpet 10 for a vehicle is manufactured, a material obtained by laminating the web-like hot melt adhesive 24 on the cushion material 30 and the tuft carpet material 20 are superimposed, and are formed after hot air heat treatment.

Then, the web-like hot melt adhesive 24
Is thermally laminated on the cushion material 30 side,
Utilizing the heat retaining effect of the cushion material 30, the degree of dissolution of the hot melt adhesive 24 is increased, and the pile removal strength and the adhesive strength are improved.

Next, FIGS. 17 to 20 show a third embodiment of the present invention.
In the tuft carpet 20 used in the third embodiment, a pile layer 21 and a base cloth layer 22 have the same configuration as that of the above-described embodiment. The feature is that the emulsion 25 is applied.

At this time, the coating weight of the latex / resin emulsion 25 is 20 to 500 g / m ² . If the basis weight is less than 20 g / m ² , the pile is likely to be missing, and if it exceeds 500 g / m ² , it becomes difficult to form and develop.

In the method of manufacturing the tufted carpet 20 according to the third embodiment, as shown in the process chart of FIG. 10, the pile yarn is tufted on the base cloth, and the repairing process and the greige machine process are performed. After applying latex or the like to the back surface of the base fabric, the tuft carpet 20 can be manufactured through a drying process.

Further, unlike the conventional sheet-like resin backing layer, the tuft carpet 20 has a structure in which the back surface of the base cloth layer 22 is covered with resin particles, so that the tuft carpet 20 has air permeability and can be reduced in weight. In addition to the structural characteristic that the sound absorbing property can be improved, the cushion material 30 and the tuft carpet 20 can be integrally heated with hot air. When manufacturing the same, after performing a heat treatment integrally with the cushion material 30, by performing simultaneous press molding, while shortening the heating time, suction or blow molding can be added at the time of press molding, shortening the molding time, As in the above-described embodiment, the productivity can be improved.

Further, although not shown, a non-molded type cushion material 30 can be applied to the tuft carpet 20 in the third embodiment, and the tuft carpet 20 is integrated when the cushion material 30 is manufactured. Thereafter, the floor carpet 10 for a vehicle can be manufactured by press molding without passing through a cushioning sheet step.

Further, as shown in FIG. 20, after the latex treatment, a resin powder or a hot melt may be coated by a spray backing or the like so as to increase the pile-pulling strength.

At this time, the basis weight of the hot melt or the spray backing is preferably in the range of ^{20 to} 250 g / m ² . If the basis weight is less than 20 g / m ² , the cushion material 30
It is necessary to perform lamination or spraying again for adhesion to the substrate. Conversely, if the basis weight exceeds 250 g / m ² , air permeability is lost, and molding time cannot be reduced.

Next, FIGS. 21 to 24 show a fourth embodiment of the present invention. As shown in the schematic views of FIGS. 21 and 22, the tuft carpet 20 is made of a pseudo backing layer 26 made of a polyester nonwoven fabric or the like. The pile yarns of the pile layer 21 are planted on the pseudo backing layer 26, and an adhesive medium 27 such as a PE / hot melt film, a resin powder, or a hot melt web is laminated on the pseudo backing layer 26.

As shown in the process chart of FIG. 23, the method of manufacturing the tufted carpet 20 according to the fourth embodiment employs a method in which the pseudo backing layer 26 is previously provided with a PE / hot melt film, resin powder, hot melt web, or the like. A material selected appropriately from the adhesive medium 27 is laminated, the pile yarn of the pile layer 21 is implanted into the pseudo backing layer 26 by tufting, and after a repairing process and a greige process, a hot air heating is performed to obtain a tufted carpet. 20 is manufactured.

When a polyester non-woven fabric is used as the pseudo backing layer 26, the basis weight is 100 to 8
00 g / m ² . If the basis weight is less than 100 g / m ² , the strength of the product is reduced, the moldability is deteriorated, the pile planting property is deteriorated, and if it exceeds 800 g / m ² , the pile planting property is deteriorated, the product moldability is deteriorated, and the product weight is reduced. It causes an increase and a decrease in air permeability.

Further, a film or a paper as the adhesive medium 27 may be used.
The basis weight of powder, web, etc. is 10 to 250 g / m²In
You. The basis weight is 10 g / m²If less than the pile blocking effect
And the adhesive force with the cushion material 30 is reduced.
250g / m ²Low air permeability above
Down.

The tuft carpet 20 of the fourth embodiment can also be reduced in weight compared to a conventional tuft carpet having a heavy resin backing layer, so that the workability of attaching the floor carpet 10 to the vehicle body can be improved. And an effect similar to that of the above-described embodiment that fuel efficiency can be improved.

The hot-melt web and the resin powder are air-permeable materials, and the hot-melt film is developed by supplying hot air to provide air permeability. By using, although not shown, the tuft carpet 20 and the cushion material 30 can be heated and pressed simultaneously at the same time, and the heating process can be shortened, and the suction or blow molding can be performed in the press forming process, and the molding time can be reduced. For example, productivity can be improved.

Further, as shown in FIG. 24, the tuft carpet 20 is subjected to a spray backing process, a hot melt web laminating process, and a PE hot melt film laminating process before and after the greige process, respectively, so that the pile unthreading strength is reduced. It can be reinforced and the adhesive strength with the cushion material 30 can be increased.

[0094]

As described above, according to the floor carpet for a vehicle and the method of manufacturing the same according to the present invention, the base fabric layer is spray-backed or laminated with a polyethylene resin or a hot-melt adhesive so that the pile is piled up. Because of the structure that enables the filling of the yarn and the adhesion to the cushion material, the weight can be significantly reduced as compared with the conventional heavy resin sheet-like backing layer, and the weight of the floor carpet can be reduced. This has the effect of simplifying assembly workability and increasing fuel efficiency.

Then, a resin material by spray backing or a web-like or film-like hot melt adhesive is laminated on the base fabric layer. By using a ventilated tuft carpet, indoor noise is reduced to the cushion material. It has an effect that sound is absorbed and the indoor sound absorbing performance can be enhanced.

Further, by using a vented tuft carpet, the tuft carpet and the cushioning material can be heated simultaneously with hot air, so that the equipment can be simplified, the heating time can be shortened, and suction can be performed during press molding. Alternatively, by adding blow molding, the molding time can be reduced, and the productivity can be greatly increased.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a configuration of a vehicle floor carpet according to the present invention.

FIG. 2 is a schematic cross-sectional view of a first embodiment of a tuft carpet used for a floor carpet for a vehicle according to the present invention.

FIG. 3 is a schematic plan view of the tuft carpet shown in FIG. 2 as viewed from the back side.

FIG. 4 is a process chart showing a method for manufacturing a tufted carpet used for a vehicle floor carpet according to a first embodiment of the present invention.

FIG. 5 is a process chart showing a method of manufacturing a floor carpet for a vehicle using a tuft carpet and a cushion material used in the first embodiment of the present invention.

6 is a process chart showing a method for manufacturing a floor carpet for a vehicle using the tuft carpet obtained in the process chart shown in FIG. 4;

7 is a process chart showing a method of manufacturing a floor carpet for a vehicle using the tuft carpet obtained in the process chart shown in FIG. 4;

8 is a process chart showing a method for manufacturing a floor carpet for a vehicle using the tuft carpet obtained in the process chart shown in FIG.

FIG. 9 is a process chart showing a modification of the method of manufacturing the tufted carpet shown in FIG. 4;

FIG. 10 is a process chart illustrating a modified example of the method for manufacturing a floor carpet for a vehicle using the tufted carpet according to the first embodiment of the present invention.

FIG. 11 is a process chart showing a modification of the method for manufacturing a floor carpet for a vehicle using the tufted carpet according to the first embodiment of the present invention.

FIG. 12 is a schematic cross-sectional view showing a second embodiment of a tuft carpet used for a floor carpet for a vehicle according to the present invention.

FIG. 13 is a schematic plan view of the tuft carpet shown in FIG. 12 as viewed from the back side.

14 is a process chart showing a method for manufacturing the tufted carpet shown in FIG.

FIG. 15 is a process chart showing a modification of the process chart shown in FIG. 14;

FIG. 16 is a process chart showing a modification of the method for manufacturing a floor carpet for a vehicle using the tufted carpet according to the second embodiment of the present invention.

FIG. 17 is a schematic sectional view showing a third embodiment of a tufted carpet used for a floor carpet for a vehicle according to the present invention.

18 is a schematic plan view of the tuft carpet shown in FIG. 17 as viewed from the back side.

19 is a process chart showing a method for manufacturing the tufted carpet shown in FIG. 17;

FIG. 20 is a process chart showing a modification of the process chart shown in FIG. 19;

FIG. 21 is a schematic sectional view showing a fourth embodiment of a tufted carpet used for a floor carpet for a vehicle according to the present invention.

FIG. 22 is a schematic plan view of the tuft carpet shown in FIG. 21 as viewed from the back side.

FIG. 23 is a process chart showing a method for manufacturing the tufted carpet shown in FIG. 21.

24 is a process chart showing a modification of the process chart showing the method for manufacturing the tufted carpet shown in FIG. 23.

FIG. 25 is an external view showing a conventional vehicle floor carpet.

FIG. 26 is a cross-sectional view showing a configuration of a conventional vehicle floor carpet.

FIG. 27 is a process chart showing a method for manufacturing a tufted carpet in a conventional floor carpet for a vehicle.

FIG. 28 is a process chart showing a conventional method of manufacturing a floor carpet for a vehicle.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Floor carpet for vehicles 20 Tuft carpet 21 Pile layer 22 Base fabric layer 23 Resin material 24 Web-like hot melt adhesive 25 Latex / resin emulsion 26 Pseudo backing layer 27 Adhesive medium 30 Cushion material

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Shinji Yoshida 3316 Miyayama, Samukawa-cho, Koza-gun, Kanagawa F-term in Kasai Kogyo Co., Ltd. 3B088 FB03 FB04 HA01

Claims (12)

[Claims] 1. A vehicular vehicle comprising: a tufted carpet having air permeability formed in accordance with the shape of a floor panel; and a cushion material laminated and integrated on the back surface of the tufted carpet. Floor carpet. 2. The tuft carpet has a pile layer on a carpet surface, a base fabric layer for planting the pile layer,
The resin material formed on the back surface of the base fabric layer by a spray backing process in order to ensure the adhesiveness between the filling function of the pile layer and the cushion material. Floor carpet for vehicles. 3. The tuft carpet has a pile layer on a carpet surface, a base fabric layer on which the pile layer is planted, and
The web-like hot-melt adhesive laminated on the back surface of the base fabric layer in order to secure the adhesiveness between the filling function of the pile layer and the cushion material, according to claim 1, characterized in that: Floor carpet for vehicles. 4. The tufted carpet has a pile layer on a carpet surface, a base fabric layer for planting the pile layer,
2. The vehicle according to claim 1, comprising a latex / resin emulsion applied to the back surface of the base fabric layer in order to secure the adhesiveness between the filling function of the pile layer and the cushion material. Floor carpet. 5. The tufted carpet is laminated with a pile layer on a carpet surface, a nonwoven fabric having a pseudo backing function for planting the pile layer,
The floor carpet for vehicles according to claim 1, comprising a powder-like, film-like, or web-like adhesive medium for ensuring the adhesiveness between the filling function of the pile layer and the cushion material. . 6. A method of manufacturing a floor carpet for a vehicle in which a cushion material is laminated and integrated on the back surface of the tuft carpet and is molded according to the surface shape of the floor panel. Adhesive media such as melt adhesives are spray coated,
Alternatively, the tuft carpet is provided with air permeability or is provided with air permeability by supplying hot air, and after laminating the tuft carpet and the cushion material and integrally heating, it is necessary to form the required shape by integral press molding. A method for manufacturing a floor carpet for a vehicle. 7. The molding cycle can be shortened by removing heat in the molding die to the outside by suction force or supplying cooling air into the molding die in an integrated press molding process of the tufted carpet and the cushioning material. The method of manufacturing a floor carpet for a vehicle according to claim 6, wherein 8. A method of manufacturing a floor carpet for a vehicle in which a cushioning material is laminated and integrated on the back surface of the tufted carpet and is formed according to the surface shape of the floor panel. A method of manufacturing a floor carpet for a vehicle, comprising simultaneously press-molding. 9. A method of manufacturing a floor carpet for a vehicle in which a cushion material is laminated and integrated on the back surface of the tuft carpet and is formed in accordance with the surface shape of the floor panel. Then, a cushion material is attached to the back surface of the tufted carpet with an adhesive. 10. A method for manufacturing a floor carpet for a vehicle in which a cushion material is laminated and integrated on the back surface of the tuft carpet and is formed in accordance with the surface shape of the floor panel. Spray hot melt, resin powder, etc., layer the material of the cushioning material in a fleece shape on it, and integrate the tuft carpet and the cushioning material by heat treatment,
A method for manufacturing a floor carpet for a vehicle, comprising press-forming to a required shape. 11. The method according to claim 6, wherein a spraying process or a laminating process of an adhesive medium such as a resin material or a hot melt adhesive is performed before and after the greige step of the tufted carpet. A method for manufacturing a floor carpet for a vehicle. 12. A method of manufacturing a floor carpet for a vehicle, wherein a cushion material is laminated and integrated on the back surface of the tuft carpet, and is formed according to the surface shape of the floor panel. After manufacturing, the adhesive medium such as resin powder or hot melt adhesive is sprayed or applied to the back of this tuft carpet, cushion material is set on it, and it is manufactured by simultaneous heating and simultaneous press molding. Of manufacturing floor carpet for vehicles.