JP2004123090A - Floor mat for automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat for an automobile capable of achieving both of sound insulating performance and sound absorbing performance. <P>SOLUTION: This floor mat 20 for the automobile has a surface layer comprising a carpet layer 21 and two or more layers of porous body layers other than the carpet layer, and is substantially composed of the porous body layers only. A composite layer comprising a material constituting the adjacent porous body layer and a foam resin is provided between the porous body layers other than the carpet layer 21. The air permeability of the composite layer is within a range of 0.1 to 10cm<SP>3</SP>/(cm<SP>2</SP>s). The air permeability of the porous body layer positioned between the carpet layer and the composite layer is preferably 15cm<SP>3</SP>/(cm<SP>2</SP>s) or more. It is preferable that the composite layer is positioned on a portion as near a back surface as possible. <P>COPYRIGHT: (C)2004,JPO

Description

The present invention relates to a floor mat for an automobile.

Conventionally, in a car, floor mats for cars have been laid on floor carpets to prevent soil, sand, etc. attached to shoes and the like from adhering to floor carpets in the car and soiling the floor carpets. I have.

By the way, in the current car, a car navigation system using voice has begun to spread, and interest in quietness in the car has been increasing. There are two methods to improve the quietness inside the vehicle. One is to improve sound insulation to reduce sound from outside the vehicle, and the other is to absorb sound to reduce the sound entering the vehicle. This is a method for improving the performance.

Conventional floor mats are made by laminating rubber or thermoplastic elastomer with anti-slip projections on the back of the carpet, so those with high sound insulation but low sound absorption are mainstream, and some have a pile structure. 2. Description of the Related Art There has been known a floor configured mainly of a sound absorbing material and having improved sound absorbing properties while sacrificing sound insulating properties (Japanese Patent Application Laid-Open No. 2001-47926).

JP 2001-47926 A

However, all of the conventional floor mats are excellent in either sound insulation or sound absorption, but are not compatible with these performances. In other words, to improve sound insulation, it is necessary to eliminate air permeability, and to increase sound absorption, it is necessary to increase air permeability.Since these are contradictory performances, it is never easy to achieve both. Was not.

The present invention has been made in order to solve such a problem, and an object of the present invention is to provide an automobile floor mat which can achieve both sound insulation and sound absorption.

The present inventors have found that when an automobile floor mat satisfies certain physical property values, it is possible to achieve both a sound insulating property and a sound absorbing property, and it is an automobile floor mat capable of improving quietness in a vehicle. This has led to the present invention.

That is, the floor mat for an automobile of the present invention is "a floor mat for an automobile composed of only two or more porous layers, and the floor mat for an automobile is made of a material other than the material constituting the adjacent porous layer. And a composite layer made of two or more types of materials, and wherein the air permeability of the composite layer is 0.1 to 10 cm ³ / cm ² · s. ” As described above, it has been found that by providing the composite layer having the air permeability of 0.1 to 10 cm ³ / cm ² · s, it is possible to achieve both sound insulation and sound absorption.

と If the car floor layer of the present invention is provided with a carpet layer as the porous layer constituting the surface layer, it is excellent in decorativeness.

When the floor mat for an automobile of the present invention includes two or more porous layers in addition to the carpet layer, the composite layer can be arranged at a position far from the surface layer, and therefore, the sound absorption on the surface side than the composite layer. This is preferable because the sound insulation can be enhanced on the back surface side of the composite layer, and it is easy to achieve both sound absorption and sound insulation.

Among the porous body layers other than the carpet layer of the floor mat for an automobile of the present invention, the porous body layer having a gas permeability of 15 cm ³ / cm ² · s or more as a porous layer on the surface layer side of the composite layer. Is particularly excellent in the sound absorption of the sound in the vehicle interior.

The rear surface of the composite layer of the automobile floor mat of the present invention has a distance from (the rear surface of the automobile floor mat) of (two-thirds of the thickness excluding the carpet layer from the rear surface of the automobile floor mat). Position), the sound inside the vehicle cabin can be efficiently absorbed on the surface layer side of the composite layer, and the sound from outside the vehicle cabin can be efficiently absorbed on the back surface side of the composite layer. Sound insulation is possible.

When the constituent material of the composite layer of the floor mat for an automobile of the present invention is a constituent material of the porous body layer adjacent to the composite layer and a foamed resin, the adhesive property between the adjacent porous body layer and the composite layer And exfoliation hardly occurs at the boundary between these layers.

自動 車 The floor mat for an automobile of the present invention can achieve both sound insulation and sound absorption.

自動 車 The floor mat for an automobile of the present invention is made of only the porous layer so as not to impair the sound absorption. The porous layer constituting the automobile floor mat of the present invention is not particularly limited as long as it is porous.For example, a carpet, a nonwoven fabric, a woven fabric, a knit, a foam, an apertured film, a microporous film, Crush rubber laminates obtained by laminating crush rubbers and bonding them with an adhesive can be exemplified.

The vehicle floor mat of the present invention may contain one or more materials other than the porous material as long as the sound absorption performance or the sound insulation performance (particularly the sound absorption performance) of the vehicle floor mat is not adversely affected. As such a material, for example, a protrusion for preventing slippage, a tape for covering the periphery of an automobile floor mat, and the like can be given.

中 で も Among these, the carpet layer is excellent in decorativeness, so that it is possible to provide a comfortable drive for passengers. Therefore, this carpet layer is preferably arranged as a porous layer constituting the surface layer of a floor mat for automobiles. Examples of the carpet include, but are not limited to, tufted carpet, needle punch carpet, curtain, hook carpet, Wilton carpet, and akisminster carpet.

In addition, if the fibers constituting the carpet include functional fibers (for example, deodorant fibers, deodorant fibers, and antibacterial and antifungal fibers), and the carpet layer constitutes the surface layer of the floor mat for automobiles, The function of the conductive fiber can be exhibited.

Further, even when the porous floor layer containing the functional fibers as described above is included as a layer other than the surface layer, the floor mat for an automobile of the present invention is composed of only the porous body layer. Function can be demonstrated.

Further, in the case where the floor mat for an automobile contains a functional resin (for example, a deodorant resin, a deodorant resin, a bactericidal and antifungal resin, etc.) in place of or in addition to the functional fibers as described above, the same applies. It can exhibit its function.

The air permeability (measured by the Frazier method specified in JIS L 1096) of the carpet layer alone that can be used as the porous body layer of the automobile floor mat of the present invention is a porous body on the back side of the carpet layer. In order to be able to utilize the sound absorbing performance of the layer, to exhibit the functions of various functional materials constituting the porous material layer on the back side of the carpet layer, and to absorb sound by interaction with the floor carpet In order to achieve excellent performance, it is preferably at least 10 cm ³ / cm ² · s, more preferably at least 15 cm ³ / cm ² · s, even more preferably at least 20 cm ³ / cm ² · s. It is sufficient that the shape of the carpet can be maintained, and the upper limit of the air permeability of the carpet layer alone is not particularly limited.

The carpet usable as the porous layer of the floor mat for an automobile of the present invention can be manufactured by a conventional method.

「The“ surface layer ”of an automobile floor mat refers to a layer that can be visually confirmed when the automobile floor mat is placed on a floor carpet.

１ One or more fiber layers can be included as the porous layer constituting the floor mat for an automobile of the present invention. The fiber layer is not particularly limited, and examples thereof include a woven fabric, a knitted fabric, and a nonwoven fabric.

The type of fiber constituting the fiber layer may be composed of any fiber component, for example, nylon fiber, vinylon fiber, vinylidene fiber, polyvinyl chloride fiber, polyester fiber, acrylic fiber. , Polyolefin-based fibers, polyurethane-based fibers, glass fibers, and the like, and one or more of such fibers can be used.

More specifically, the porous body layer composed of a fiber layer can include one or more ultrafine nonwoven fabric layers containing ultrafine fibers having a fiber diameter of 10 μm or less. In this ultrafine nonwoven breathable (measured by Frazier method prescribed in JIS L 1096) is 10~50cm ³ / cm ² · s, close to the breathability of the composite layer, the ultrafine nonwoven fabric composite layer It becomes a constituent material, and it is easy to form a composite layer having air permeability of 0.1 to 10 cm ³ / cm ² · s in cooperation with a second material such as a resin.

In addition, the porous body layer composed of a fiber layer may include one or more layers of a woven fabric (for example, a plain woven fabric or a twill woven fabric) using split yarns and / or flat tapes. In addition, since the permeable portion of the woven fabric is limited to the region surrounded by the warp and the weft, and the permeable property can be suppressed to a low level, the woven fabric becomes a material constituting the composite layer, and the second material such as resin is used. Together, it is easy to form a composite layer having air permeability of 0.1 to 10 cm ³ / cm ² · s.

Furthermore, as the porous body layer composed of a fiber layer, one or more bulky nonwoven fabrics can be included. When this bulky nonwoven fabric is included and is located closer to the surface layer than the composite layer, the sound absorbing performance can be improved by increasing the distance from the surface of the automobile floor mat to the composite layer. In addition, this bulky nonwoven fabric becomes a material constituting the composite layer, and it is easy to form a composite layer having air permeability of 0.1 to 10 cm ³ / cm ² · s in cooperation with a second material such as a resin.

Note that the "bulky nonwoven layer" herein layer thickness means a more nonwoven layers 1 mm, thickness in this case refers to a value at 10g load per 1 cm ^2. The thicker the bulky nonwoven fabric layer is, the better the sound absorbing performance is, but it is preferably 15 mm or less in practical use of an automobile floor mat.

The basis weight of such a bulky nonwoven fabric layer is preferably 50 to 1500 g / m ² , and more preferably 70 to 1000 g / m ² so that the floor mat for automobiles can be reduced in weight. Further, the apparent density (= basis weight / thickness) of the bulky nonwoven fabric is preferably a 0.02~0.3g / cm ^3, and more preferably 0.035~0.25g / cm ^3.

Such a bulky nonwoven fabric is prepared, for example, by (1) forming a fiber web by a dry method and then performing needle punching, and (2) forming a fiber web containing heat-fusible fibers by a dry method, Production by fusing the heat-fusible fibers by applying heat under a pressure as low as possible to adjust the thickness or thickness, or (3) laminating a melt blown nonwoven fabric having a fineness of 6.6 dtex or more. can do.

In addition to the above-mentioned ultrafine nonwoven fabric layer, a woven fabric (for example, a plain woven fabric, a twill woven fabric) layer using a split yarn and / or a flat tape, or a bulky nonwoven fabric layer as a porous body layer composed of a fiber layer, a fused nonwoven fabric layer , A hydroentangled nonwoven fabric, a spunbonded nonwoven fabric, a meltblown nonwoven fabric, and scrap felt can also be used.

The floor mat for an automobile of the present invention can include one or more foam layers as a porous layer made of resin. When this foam layer is included, various functions such as cushioning properties can be added to the floor mat for automobiles. The foam layer is preferably open cells so that the sound absorbing performance does not deteriorate. When the floor mat for an automobile contains a functional substance (for example, a deodorant, an aromatic, or an antibacterial and antifungal agent), the foam layer that is an open cell does not impair the function. .

Although the resin constituting the foam layer is not particularly limited, for example, urethane resin, acrylic resin, styrene-butadiene copolymer resin, styrene-butadiene rubber, nitrile-butadiene rubber, isoprene rubber, nitrile rubber, or Examples include natural rubber. These resins or rubbers can be used alone or as a mixture.

The foaming ratio (density before foaming / density after foaming) of the foam constituting the foam layer is not particularly limited, but the larger the foaming ratio, the better the cushioning property when stepped on. However, since settling is likely to occur during long-term use, the expansion ratio is preferably 1.2 to 20 times, and more preferably 2 to 10 times.

Basis weight of such a foam layer, so that it can reduce the weight of the automotive floor mat is preferably from 200 to 1000 g / ^{m 2,} and more preferably 300 to 800 g / ^{m 2.} Further, the thickness of the foam layer (the thickness of the convex portion when the foam has an uneven structure) is suitably about 1 to 7 mm, and the apparent density (= weight / thickness) is 0.03 to is preferably from 1 g / cm ^3, and more preferably 0.04~0.5g / cm ^3.

発 泡 The foam constituting such a foam layer can be obtained by an ordinary method.

Such a foam layer may be located anywhere, but if the car floor mat has the carpet layer and the fiber layer as described above, the foam layer may be located between the carpet layer and the fiber layer. It preferably has a layer. With such an arrangement, the adhesion between the carpet layer and the fiber layer can be improved, and the carpet layer and the fiber layer can be prevented from peeling during use of the floor mat for an automobile. In addition, it is preferable that such a foam layer constitutes the back surface layer of the floor mat for an automobile because slip of the floor mat for an automobile can be prevented. When the foam layer constitutes the back layer of the automobile floor mat as described above, if the foam layer has an uneven surface on the exposed surface side, the slip of the automobile floor mat can be more effectively prevented. it can.

「The“ backside layer ”in the present invention refers to a layer that directly contacts the floor carpet.

The floor mat for an automobile of the present invention includes at least one composite layer containing two or more materials including at least one material other than the material constituting the porous layer adjacent to the composite layer. Here, “materials other than the material constituting the porous body layer adjacent to the composite layer” means (1) the composite layer is in contact with the two porous body layers on both surfaces thereof, When there is an adjacent porous material layer, it means a material other than the material constituting one porous material layer of the two porous material layers, and (2) the composite layer has one material only on one side thereof. When in contact with the porous material layer, that is, when there is one adjacent porous material layer, it means a material other than the material constituting the porous material layer.

For example, when there is one adjacent porous body layer (for example, when the adjacent porous body layer is made of the material A), the composite layer is (1) a combination of the material A and one or more other materials, Or (2) a combination of two or more materials other than the material A. Further, when there are two adjacent porous body layers (for example, when one adjacent porous body layer is made of material A and the other adjacent porous body layer is made of material B), these porous bodies are used. The composite layers located between the layers are (1) a combination of material A and material B, (2) a combination of material A and one or more materials other than material A and material B, (3) It consists of a combination of the material B and one or more materials other than the materials A and B, or (4) a combination of two or more materials other than the materials A and B.

(4) The floor mat for an automobile of the present invention is composed of only the porous layer as described above, and thus has excellent sound absorbing performance. Note that the composite layer is one mode of the porous material layer, as can be seen from the fact that it has air permeability. In addition, since the composite layer mainly exhibits sound insulation performance, a porous material layer exhibiting sound absorption performance is required. Therefore, the automobile floor mat of the present invention comprises two or more layers. In particular, when two or more porous material layers are provided in addition to the carpet layer, the composite layer can be arranged at a position far from the surface layer. This is preferable because sound insulation can be enhanced on the back surface side, and it is easy to achieve both sound absorption and sound insulation. For example, the above effect can be obtained by arranging a composite layer between porous layers other than the carpet layer, or arranging a composite layer as a back layer.

As described above, the floor mat for an automobile according to the present invention has a sound absorbing property and a gas permeability of 0.1 to 10 cm ³ / cm ² · s by being constituted only of the porous material layer. By providing the composite layer of the above, sound insulation is provided. If the air permeability of the composite layer is less than 0.1 cm ³ / cm ² · s, the sound is likely to be reflected, so that the sound absorption performance tends to deteriorate. If the air permeability exceeds 10 cm ³ / cm ² · s, Since the sound insulation performance tends to deteriorate because sound cannot be reflected, a preferable air permeability is 0.1 to ⁷ cm ³ / cm ² · s, and a more preferable air permeability is 0.1 to ⁵ cm ³ / cm ² · s. s, and more preferable air permeability is 0.1 to ⁴ cm ³ / cm ² · s.

「The“ air permeability of the composite layer ”of the present invention refers to a value obtained by collecting the composite layer from an automobile floor mat and measuring the composite layer by the Frazier method specified in JIS L # 1096. When the composite layer contains a material constituting the adjacent porous body layer, it may be difficult to collect only the composite layer. In this case, a sample in which the adjacent porous body layer and the composite layer are integrated is collected, the gas permeability of the sample is measured, and the gas permeability is regarded as the gas permeability of the composite layer. That is, only the composite layer cannot be collected because the composite layer contains the adjacent porous body layer constituent material, and the composite layer is made of a material other than the adjacent porous body layer constituent material (the second material). ), The pressure loss in the composite layer greatly affects the air permeability of the sample in which the porous layer and the composite layer are integrated, so that the porous layer and the composite layer are integrated. The sample thus obtained is sampled and its air permeability is measured, and the air permeability is regarded as the air permeability of the composite layer.

複合 The composite layer of the present invention does not need to be a single layer, and may be two or more layers. In the case where two or more layers are present, it is preferable that a composite layer having a small air permeability is arranged in order from the front surface to the rear surface of the floor mat for an automobile. This is so as not to impair the sound absorption. Also, the composite layer may be located anywhere. For example, a porous layer, a back layer, and the like can be given.

複合 Since the composite layer of the present invention is made of two or more materials including materials other than the material constituting the adjacent porous material layer, it is easy to have the above-mentioned air permeability. This composite layer may or may not contain the material constituting the adjacent porous material layer, but if it does, it has excellent adhesion between the adjacent porous material layer and the composite layer, and This is preferable because peeling hardly occurs.

As a material other than the material constituting the adjacent porous body layer, for example, the same carpet as the porous body capable of constituting the porous body layer, nonwoven fabric (ultrafine nonwoven fabric, bulky nonwoven fabric, fused nonwoven fabric, hydroentangled nonwoven fabric, Spunbond nonwoven fabric, meltblown nonwoven fabric, scrap felt, etc.), woven fabric (split yarn and / or woven fabric using flat tape (eg, plain woven fabric, twill woven fabric, etc.)), knitted fabric, foam, apertured film, microporous film, A crush rubber laminate obtained by laminating crush rubber and bonding with an adhesive, a fiber (a fiber similar to the fiber constituting the fiber layer), or a foamed or unfoamed resin can be used.

The composite layer of the present invention is composed of two or more of the above-mentioned materials. Preferred combinations include (1) carpet, nonwoven fabric (ultrafine nonwoven fabric, bulky nonwoven fabric, fused nonwoven fabric, hydroentangled nonwoven fabric, spunbonded nonwoven fabric) , Melt-blown nonwoven fabric, scrap felt, etc.), woven fabric (split yarn and / or woven fabric using flat tape (eg, plain woven fabric, twill woven fabric, etc.), knitted fabric, etc., and combination of resin with resin, (2) composition And combinations of two or more kinds of resins different from each other. In particular, when the constituent material of the composite layer is a constituent material (particularly, a fiber or a fiber aggregate) of the porous body layer adjacent to the composite layer and a foam resin, the air permeability is easily obtained, and the adjacent porous body layer is further formed. This is a preferred composite layer because it has excellent adhesion between the layer and the composite layer and does not easily peel off at the boundary between these layers.

In addition, as a resin that can constitute the composite layer, for example, isobutylene-maleic anhydride copolymer, acrylonitrile-styrene-acryl rubber copolymer, acrylonitrile-ethylene-styrene copolymer, acrylic resin, acrylonitrile-styrene copolymer, acrylonitrile -Butadiene-styrene copolymer, styrene-butadiene copolymer, ethylene-vinyl acetate copolymer, ethylene-vinyl chloride-vinyl acetate copolymer, epoxy resin, xylene resin, phenol resin, polyimide resin, polyurethane resin, melamine resin, urea resin , Styrene-butadiene rubber, butadiene rubber, isoprene rubber, nitrile-butadiene rubber, butyl rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, urethane rubber, silicone Ngomu, nitrile rubber, or natural rubber, and the like.

Such a composite layer is formed, for example, by bonding an aqueous adhesive (for example, an emulsion adhesive, a dispersion adhesive, or the like), a solvent adhesive, or a hot melt adhesive when bonding porous bodies. It can be formed by interposing between porous bodies and allowing these adhesives to enter at least one of the porous bodies. The amount of the adhesive, the degree of pressing, the viscosity of the adhesive, the compatibility between the adhesive and the porous body, the suction of the porous body by capillary action, and the like are appropriately adjusted to obtain the composite layer having air permeability. It can be.

Further, when the adjacent porous body layer is a foam layer, foamed latex is applied to the porous body, and a part of the foam resin enters the porous body to form a composite layer. At the same time, a foam layer can be formed. At this time, by appropriately adjusting the degree of pressing, the viscosity of the foamed latex, or the time from the application of the foamed resin to the porous body to the pressing, the composite layer having air permeability as described above is obtained. It can be.

In the automobile floor mat of the present invention, the rear surface of the composite layer has a surface from (the rear surface of the automobile floor mat) to (two-thirds of the thickness of the rear surface of the automobile floor mat excluding the carpet layer ( It is preferably located within a range up to a distance of 1/2). When located within this range, sound in the vehicle cabin can be efficiently absorbed by effectively utilizing the sound absorbing properties of the porous layer on the surface layer side of the composite layer, and at the same time, the composite layer This is because sound from outside the vehicle cabin can be efficiently shielded on the back side of the vehicle.

In the case where the rear surface of the vehicle floor mat has an uneven structure such as a projection on the exposed surface, the flat portion (recess) excluding the convex portion is considered as the rear surface of the vehicle floor mat. The “thickness excluding the carpet layer” refers to a value obtained by applying a load of 50 g / cm ² to an automobile floor mat cut perpendicularly to the surface and, after 10 seconds, from the direction parallel to the automobile floor mat surface. It refers to the thickness from the back surface of the car floor mat to the primary backing of the carpet (back surface) when the cut surface is observed.

An automotive floor mat having a composite layer at such a position is, for example, a laminate in which two or more porous layers are laminated in addition to a carpet layer, and a resin is supplied and supplied between porous layers other than the carpet layer. It can be manufactured by forming a composite layer by allowing a part or all of the resin to enter the porous body, and supplying the resin to the back side surface of the porous body layer other than the carpet layer, and a part or the supplied resin. It can be manufactured by forming a composite layer by allowing the whole to enter the porous body.

In the automobile floor mat of the present invention, since the above-described composite layer having air permeability mainly contributes to sound insulation, the porous layer on the surface layer side of the composite layer has air permeability (JIS L 1096). It is preferable to provide a porous material layer (excluding a carpet layer) having a value of not less than 15 cm ³ / cm ² · s (measured by a prescribed Frazier method) so as to be excellent in sound absorbing property of the sound in the passenger compartment. . It is more preferably at least 20 cm ³ / cm ² · s, still more preferably at least 25 cm ³ / cm ² · s, and the upper limit is not particularly limited.

The preferred combination of the porous layer of the automobile floor mat of the present invention is as follows: (1) carpet layer-composite layer of pile and foam resin-foam layer-fiber layer in order from the surface layer to the back layer. (2) Carpet layer-Composite layer of pile and foam resin-Foam layer-Composite layer of fiber sheet and foam resin-Foam layer (3) carpet layer-composite layer of pile and foam resin-foam layer-composite layer of fiber layer constituent material and foam resin-fiber layer-composite layer of fiber layer constituent material and foam resin-foam Body layer, (4) Carpet layer-Composite layer of pile and foam resin-Foam layer-Composite layer of two types of foam resins-Foam layer, (5) Carpet layer-Pile, adhesive resin and fiber layer Composite layer with constituent material-fiber layer-between fiber layer and adhesive resin (6) Carpet layer-Composite layer of pile and foam resin-Foam layer-Composite layer of fiber layer constituent material and foam resin, (7) Carpet layer-Composite of pile and foam resin Layer-foam layer-composite layer of fiber sheet and foam resin, (8) carpet layer-composite layer of pile and foam resin-foam layer-composite layer of fiber layer constituent material and foam resin-fiber Layer-Composite layer of fiber layer constituent material and foam resin, (9) Carpet layer-Composite layer of pile and foam resin-Foam layer-Composite layer of two types of foam resin, (10) Carpet layer- A composite layer of a pile, an adhesive resin, and a material constituting a fiber layer, a fiber layer, and a composite layer of a fiber layer and an adhesive resin may, for example, be mentioned.

When the air permeability (the value obtained by the JIS L 1096: 1999 8.27.1 A method (Fragile method)) of the entire automobile floor mat of the present invention is 0.1 cm ³ / cm ² · s or more, the floor carpet Excellent sound absorption due to interaction with In addition, functional fibers (for example, deodorant fibers, deodorant fibers, antibacterial and antifungal fibers) and functional resins (for example, deodorants, deodorants, fragrances, antibacterial and antifungal agents) are contained in floor mats for automobiles. When these exist, these functions can be exhibited efficiently. Since the air permeability of the entire automobile floor mat greatly depends on the air permeability of the composite layer, the air permeability of the entire automobile floor mat is preferably 0.1 to ⁷ cm ³ / cm ² · s, and more preferably the air permeability. The air permeability is 0.1 to ⁵ cm ³ / cm ² · s, and the more preferable air permeability is 0.1 to ⁴ cm ³ / cm ² · s.

In addition, it is preferable that the exposed surface of the back surface layer has an uneven structure because the uneven structure bites into the floor carpet and can prevent the floor mat for automobile from shifting.

Since such an automobile floor mat of the present invention comprises only a porous layer, it is lighter than a conventional automobile floor mat using rubber, thermoplastic elastomer, or the like. That is, the total weight of the porous body layer other than the carpet layer of the automobile floor mat of the present invention is about 400 to 1350 g / m ² , and the conventional automobile floor mat using the rubber or thermoplastic elastomer is used. Since the total basis weight of the layers other than the carpet layer is about 1700 to 2400 g / m ^2, it is lighter than the conventional one.

The method for manufacturing the floor mat for an automobile of the present invention is not particularly limited. For example, after preparing the porous body constituting each porous body layer, (1) the porous body is provided between the porous bodies. After disposing a porous sheet (for example, nonwoven fabric, net, etc.) that can be melted at a temperature that has no adverse effect, the porous sheet is melted at a temperature at which the porous sheet can be melted, and the porous sheet melt is introduced into at least one of the porous bodies. (2) supplying a hot melt resin melt between porous bodies, applying pressure, and injecting the hot melt resin melt into at least one of the porous bodies; (3) melting one or more resins constituting the porous body and injecting the melt into at least one of the porous bodies to form a composite layer (4) A water-based adhesive or a solvent-based adhesive is supplied between the porous bodies, and these adhesives enter at least one of the porous bodies to form a composite layer and be integrated at the same time. (5) When a foam is used as the porous body, the latex is foamed and then applied to the porous body, and a part of the foam is made to enter the inside of the porous body to form a composite layer and foam simultaneously. It can be produced by a method of forming a body layer, and the like. When the porous body is integrated, the melting temperature, the degree of pressure, the amount of the adhesive, the viscosity of the adhesive, the compatibility between the adhesive and the porous body, the suction of the porous body by capillary action, etc. The composite layer having an air permeability of 0.1 to 10 cm ³ / cm ² · s can be formed by appropriately adjusting the thickness.

In addition, instead of forming a composite layer when integrating the porous bodies as described above, a composite material in which another material is composited with the porous body in advance is prepared, and the composite material is integrated. This also makes it possible to manufacture the floor mat for an automobile of the present invention. For example, by immersing a fiber aggregate (nonwoven fabric, woven fabric, etc.) in a foam resin to form a composite material composed of the fiber aggregate and the foam resin, the composite material is used as the above-described porous body. Then, the composite material can be manufactured by laminating the composite material with another porous body and then stitching and integrating the surroundings.

In addition, when the end of the car floor mat is unsightly or there is a risk that the fibers may fall off due to the provision of the fiber layer as the porous body layer, the surroundings of the car floor mat may be over-locked with a thread. It is preferable to cover and conceal the periphery of the vehicle floor mat by tape processing, to heat-melt the periphery of the vehicle floor mat, or to cover the periphery of the vehicle floor mat with resin.

自動 車 To facilitate understanding of the floor mat for an automobile of the present invention, a description will be given based on FIG. 1 which is an example of a schematic cross-sectional view of the floor mat for an automobile.

An automobile floor mat 20 shown in FIG. 1 includes a carpet layer 21, a first composite layer 22 composed of a pile and a foam, a first foam layer 23, and a nonwoven fabric and a foam in order from the front layer to the back layer. A second composite layer 24 and a second foam layer 25 are provided. The carpet layer 21 includes a pile layer 21a and a primary backing layer 21b. The first foam layer 23 is formed by applying a foam to the carpet layer 21. When the foam resin constituting the first foam layer 23 is applied to the carpet, a part of the foam resin enters the pile to form the first composite layer 22. The second composite layer 24 is formed by applying a foam resin constituting the first foam layer 23 and laminating the nonwoven fabric before drying, thereby allowing a part of the foam resin to enter the inside of the nonwoven fabric. It is formed by applying a foam resin that constitutes the second foam layer 25 on the upper portion, thereby allowing a part of the foam to enter the inside of the nonwoven fabric. Therefore, the second composite layer 24 is in a state where three types of materials, that is, the nonwoven fabric, the foam constituting the first foam layer 23, and the foam constituting the second foam layer 25 are mixed. As described above, since the second composite layer 24 is in a state where the foam has entered the inside of the nonwoven fabric, the first composite layer 23 and the second composite layer 24 and the second composite layer 24 and the second composite layer 25 It is excellent in adhesiveness with, and peeling between these layers hardly occurs. The second foam layer 25 constituting the back layer is formed by applying a foam to the nonwoven fabric as described above, and by embossing before or after drying, an uneven structure is formed on the exposed surface. I have. The anti-slip property of the floor mat 20 for automobiles is improved by this uneven structure. The rear surface S of the second composite layer 24 is located at a distance of 2/3 of the thickness D excluding the carpet layer from the rear surface R of the car floor mat to the rear surface R of the car floor mat. ), And the first foam layer 23 has air permeability of 15 cm ³ / cm ² · s or more, so that sound can be isolated on the back side of the second composite layer 24 and the second composite layer 24 The porous body layer (particularly, the first foam layer 23) on the surface side of the layer 24 has excellent sound absorbing properties. In addition, since the car floor mat 20 includes the carpet layer 21, it has excellent decorativeness. In addition, since it has the 1st foam layer 23 and the 2nd foam layer 25, cushioning property is provided. Furthermore, the first foam layer 23 relieves the uneven structure due to the pile on the primary base cloth 21b side of the carpet, so that the carpet can be in close contact with the second composite layer 24, so that the carpet layer 21 and the second composite layer 24 Difficult to peel off.

The floor mat for an automobile of the present invention is used by placing it on a floor carpet of an automobile. If the floor carpet of an automobile has excellent sound absorbing properties, it is synergistic with the floor mat for an automobile of the present invention. Due to the effect, it is more excellent in sound absorption. For example, as disclosed in WO 98/18657, a porous cushion layer having an uneven surface so that a partial air layer can be formed, and a hard layer (500 to has a total resistance to air flow 2500Nsm ^-3, has a basis weight of 300~2000g / ^{m 2,} having a hardness of 0.005～10.5Nm) and having a carpet layer, unevenness of the cushion layer When the floor mat for an automobile of the present invention is placed on a floor carpet arranged so as to be in contact with the vehicle body, the sound absorbing property is particularly excellent.

実 施 Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Example 1)
A pile layer made of polypropylene fiber having a basis weight of 500 g / m ² , and a spunbond nonwoven fabric (primary base cloth) made of polyester fiber having a basis weight of 120 g / m ² for supporting the pile layer, and styrene is provided on the back surface of the primary base cloth. -Tufted carpet (breathability: 55 cm ³ / cm ² · s) coated with a latex containing butadiene rubber as a main component (dry weight: 240 g / m ² ), and a lamination length of 25 g / m ^2. A fiber nonwoven fabric (manufactured by Teijin Limited, Unicell, air permeability: 215 cm ³ / cm ² · s) was prepared.

Next, a styrene-butadiene rubber latex and a natural rubber latex are mixed at a weight ratio of 30:70, and the mixed rubber latex foamed by mechanical foaming is mixed with the toughness so that the basis weight (at the time of drying) becomes 700 g / m ^2. It was applied to the back of the ted carpet. Before drying the mixed rubber latex, the above laminated nonwoven fabric is laminated and left for 1 minute to allow the mixed rubber latex to enter the inside of the laminated nonwoven fabric. Ted carpet, mixed rubber first foam (open cell, expansion ratio: 3 times, thickness: 3 mm, apparent density: 0.23 g / cm ³ ) and laminated extension method long-fiber nonwoven fabric are integrated into a precursor composite Was manufactured.

Next, a styrene-butadiene rubber latex and a natural rubber latex were mixed at a ratio of 30:70 on the surface of the laminated composite extended fiber nonwoven fabric of the precursor composite, and the mixed rubber latex foamed by mechanical foaming was dried (at the time of drying). ) To 540 g / m ^2, and a part of the mixed rubber latex is allowed to enter the inside of the laminated nonwoven fabric, and then dried. The precursor composite and the mixed rubber second foam (open cells, The expansion ratio: 2.5 times, the thickness of the projections: 2 mm, and the apparent density: 0.27 g / cm ³ ) were integrated to produce an automobile floor mat. Before the drying was completed, the mixed rubber second foam was embossed to form a waffle-like (lattice-like) uneven structure on the exposed surface.

As shown in FIG. 1, this automotive floor mat has a tufted carpet layer, a first composite layer composed of a pile and a mixed rubber foam, and a mixed rubber first foam layer (air permeability: 57 cm ³ / cm) in order from the surface layer. ² · s), a second composite layer the same foam as the foam is combined integrally enters constituting the first and second mixing rubber foam layer in the stacking spreading method Spunbond, the uneven structure on the exposed surface Rubber foam (air permeability: 45 cm ³ / cm ² · s). The air permeability of the whole floor mat for automobiles was 0.15 cm ³ / cm ² · s. The thickness of the car floor mat excluding the tufted carpet layer was 5 mm, the air permeability was 0.2 cm ³ / cm ² · s, and the basis weight was 1265 g / m ² . Further, the rear surface of the second composite layer is located at a position 2 mm from the rear surface of the floor mat for an automobile, the air permeability of the second composite layer is 0.2 cm ³ / cm ² · s, and the rear surface of the first composite layer is The side surface was at a position 5 mm from the back of the automobile floor mat, and the air permeability of the first composite layer was 15 cm ³ / cm ² · s.

(Example 2)
The same tufted carpet as in Example 1, and a needle-punched non-woven fabric (basis weight: 70 g) composed of 70 mass% of polyester fiber having a fineness of 7.8 dtex and a fiber length of 76 mm and 30 mass% of polyester fiber having a fineness of 3.3 dtex and a fiber length of 51 mm / M ² , thickness: 0.4 mm, apparent density: 0.18 g / cm ³ ), and air permeability: 400 cm ³ / cm ² · s).

Next, the same foamed mixed rubber latex as in Example 1 was applied to the back surface of the tufted carpet so that the basis weight (at the time of drying) was 700 g / m ^2, and before the mixed rubber latex was dried, the needle-punched nonwoven fabric was removed. After the mixed rubber latex is allowed to enter the inside of the needle-punched nonwoven fabric for 1 minute by superposition, the mixed rubber latex is put into a drier, and the tufted carpet and the first mixed rubber foam (open cells, expansion ratio: 3 times, thickness) : 3 mm, apparent density: 0.23 g / cm ³ ) and the needle-punched nonwoven fabric were integrated to produce a precursor composite.

Next, the same foamed mixed rubber latex as in Example 1 was applied to the surface of the needle-punched nonwoven fabric of the precursor composite so that the basis weight (at the time of drying) was 540 g / m ^2, and a part of the mixed rubber latex was applied. After penetrating into the inside of the needle-punched nonwoven fabric, it is dried, and the precursor composite and the mixed rubber second foam (open-cell, expansion ratio: 2.5 times, thickness of convex portion: 2 mm, apparent density: 0.27 g / cm ³ ) to produce an automobile floor mat. Before the drying was completed, the mixed rubber second foam was embossed to form a waffle-like (lattice-like) uneven structure on the exposed surface.

As shown in FIG. 1, this automotive floor mat has a tufted carpet layer, a first composite layer composed of a pile and a mixed rubber foam, and a mixed rubber first foam layer (air permeability: 57 cm ³ / cm) in order from the surface layer. ² · s), a second composite layer in which the same foam as the foams constituting the first and second mixed rubber foam layers enters the needle-punched non-woven fabric and is integrated integrally, and a mixed rubber having an uneven structure on the exposed surface A second foam layer (air permeability: 45 cm ³ / cm ² · s) was provided. The air permeability of the entire floor mat for automobiles was 2.2 cm ³ / cm ² · s. The thickness of the car floor mat excluding the tufted carpet layer was 5 mm, the air permeability was 2.8 cm ³ / cm ² · s, and the basis weight was 1265 g / m ² . Further, the rear surface of the second composite layer is located at a position 2 mm from the rear surface of the floor mat for an automobile, the air permeability of the second composite layer is 3.8 cm ³ / cm ² · s, and the rear surface of the first composite layer is The side surface was at a position 5 mm from the back of the automobile floor mat, and the air permeability of the first composite layer was 15 cm ³ / cm ² · s.

(Comparative Example 1)
A tufted carpet similar to that in Example 1 and a styrene-butadiene-styrene elastomer sheet (basis weight: 1350 g / m ² ) were prepared.

Next, after laminating the tufted carpet and the styrene-butadiene-styrene elastomer sheet such that the primary base fabric side of the tufted carpet is in contact with the styrene-butadiene-styrene elastomer sheet, a press plate having a nib forming groove is provided. After heating the tufted carpet and the styrene-butadiene-styrene elastomer sheet, they were pressed to perform integration and nib formation, and the tufted carpet layer, the carpet-elastomer composite layer, and the elastomer layer were sequentially formed from the surface layer. An automotive floor mat (with air permeability: 0 cm ³ / cm ² · s, basis weight: 2210 g / m ² ) was manufactured. The air permeability of the carpet-elastomer composite layer was 0 cm ³ / cm ² · s.

(Comparative Example 2)
The same tufted carpet as in Example 1 and the same needle-punched nonwoven fabric as in Example 2 were prepared.

Next, the same foamed mixed rubber latex as in Example 1 was applied to the back surface of the tufted carpet so that the basis weight (at the time of drying) was 700 g / m ^2, and before the mixed rubber latex was dried, the needle-punched nonwoven fabric was removed. Superimposed, immediately put into a dryer, tufted carpet and mixed rubber first foam (open cell, expansion ratio: 3 times, thickness: 3 mm, apparent density: 0.23 g / cm ³ ) and needle-punched nonwoven fabric Were integrated to produce a precursor composite. The mixed rubber first foam partially penetrates into the needle-punched nonwoven fabric to form a composite layer in which the needle-punched nonwoven fabric alone and the needle-punched nonwoven fabric and the mixed rubber first foam are combined and integrated. I was

Next, the same foamed mixed rubber latex as in Example 1 was applied to the surface of the needle-punched nonwoven fabric of the precursor composite so that the basis weight (at the time of drying) was 540 g / m ^2, and a part of the mixed rubber latex was applied. After penetrating into the inside of the needle-punched nonwoven fabric, it is dried, and the precursor composite and the mixed rubber second foam (open-cell, expansion ratio: 2.5 times, thickness of convex portion: 2 mm, apparent density: 0.27 g / cm ³ ) to produce an automobile floor mat. Before the drying was completed, the mixed rubber second foam was embossed to form a waffle-like (lattice-like) uneven structure on the exposed surface.

As shown in FIG. 1, this automotive floor mat has a tufted carpet layer, a first composite layer composed of a pile and a mixed rubber foam, and a mixed rubber first foam layer (air permeability: 57 cm ³ / cm) in order from the surface layer. ² · s), a second composite layer in which the same foam as the foams constituting the first and second mixed rubber foam layers enters the needle-punched non-woven fabric and is integrated integrally, and a mixed rubber having an uneven structure on the exposed surface A second foam layer (air permeability: 45 cm ³ / cm ² · s) was provided. In addition, the air permeability of the whole car floor mat was 7 cm ³ / cm ² · s. The thickness of the car floor mat excluding the tufted carpet layer was 5 mm, the air permeability was 8.3 cm ³ / cm ² · s, and the basis weight was 1265 g / m ² . Further, the rear surface of the second composite layer is located at a position 2 mm from the rear surface of the floor mat for an automobile, the air permeability of the second composite layer is 11.0 cm ³ / cm ² · s, and the rear surface of the first composite layer is The side surface was at a position 5 mm from the back of the automobile floor mat, and the air permeability of the first composite layer was 15 cm ³ / cm ² · s.

(Evaluation of sound insulation performance)
According to JIS A1416 (method of measuring sound transmission loss in a laboratory), the sound transmission loss of the floor mats for automobiles of Examples 1-2 and Comparative Examples 1-2 was measured. The result was as shown in FIG. It is said that if the difference in sound transmission loss is 5 dB or more, the difference is at a level that can be distinguished by ordinary people.

(Evaluation of sound absorption performance)
Using a measuring instrument manufactured by Brüel & Kjær, ISO 10534-2 "Acoustics-Determination of sound absorption coefficient and impedience in impedance tubes, Part2: trans-first and second-second examples based on the first and second examples. The sound absorption coefficients of the floor mats for automobiles 1 and 2 were measured. The result was as shown in FIG.

As is clear from the results of FIGS. 2 and 3, the automobile floor mat of the present invention was excellent in both sound insulation performance and sound absorption performance. On the other hand, the car floor mat of Comparative Example 1 is excellent in sound insulation performance but has poor sound absorption performance, and the car floor mat of Comparative Example 2 is excellent in sound absorption performance but is sound insulation. The performance was poor. In addition, from the comparison between Example 1 and Comparative Example 1, the composite layer having the air permeability of 0.1 cm ³ / cm ² · s or more has excellent sound absorbing performance, and the comparison between Example 2 and Comparative Example 2. It was also confirmed that the composite layer having an air permeability of 10 cm ³ / cm ² · s or less had excellent sound insulation.

An example of a schematic cross-sectional view of an automobile floor mat of the present invention Graph showing the relationship between frequency and sound transmission loss Graph showing the relationship between frequency and sound absorption coefficient

Explanation of reference numerals

Reference Signs List 20 floor mat for car 21 carpet layer 22 first composite layer 23 first foam layer 24 second composite layer 25 second foam layer

Claims (6)

An automotive floor mat comprising only two or more porous material layers, wherein the automotive floor mat comprises a composite layer comprising two or more types of materials including a material other than a material constituting an adjacent porous material layer. A floor mat for automobiles, comprising: a composite layer having an air permeability of 0.1 to 10 cm ³ / cm ² · s. The automobile floor mat according to claim 1, further comprising a carpet layer as a porous layer constituting the surface layer. The automobile floor mat according to claim 2, wherein two or more porous layers are provided in addition to the carpet layer. Among the porous body layers other than the carpet layer, a porous body layer having air permeability of 15 cm ³ / cm ² · s or more is provided as a porous body layer closer to the surface layer than the composite layer. The floor mat for vehicles according to claim 3 which does. The rear surface of the composite layer is located within a range from (the rear surface of the automobile floor mat) to (a position at a distance of two-thirds of the thickness excluding the carpet layer from the rear surface of the automobile floor mat). The floor mat for vehicles according to any one of claims 2 to 4, wherein the floor mat is formed. The automotive floor mat according to any one of claims 1 to 5, wherein constituent materials of the composite layer are a constituent material of a porous body layer adjacent to the composite layer and a foam resin.

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