JP2006298125A - Lightweight floor mat for automobile with sound absorbing effect - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat for an automobile light in weight, excellent in a slip-preventive property, favorable in sound absorbing performance and environment-friendly. <P>SOLUTION: An upper layer carpet using polyester filament yarn single yarn fineness of which is 20 to 60 decitex and a nonskid layer using a cut pile carpet using polyester filament yarn single yarn fineness of which is 20 to 60 decitex are laminated to each other with a polyethylene resin film, pile length of the cut pile carpet of the nonskid layer is made less than 5 mm and air permeability is made 1 to 50 (cm<SP>3</SP>/cm<SP>2</SP>second). Consequently, there is provided the floor mat for the automobile excellent in the slip-preventive property, light in weight and favorable in sound absorbing performance. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

The present invention relates to a technique for an automobile floor mat that is used by being placed on a tufted carpet or a needle punched carpet previously laid on the floor of an automobile.

Conventionally, in automobiles, dirt, sand, mud, gravel, or rainwater adhering to shoes, etc., adheres to tufted carpets and needle punch carpets laid on the floor of automobiles, and the interior of automobiles has become dirty. In order to prevent this, an automobile floor mat is laid.

As this automobile floor mat, as disclosed in Patent Document 1, there is known a floor mat made of a surface material such as a carpet and a backing material such as a synthetic resin or rubber that supports the surface material. In such a floor mat, durability is imparted by the backing material, and an anti-slip effect is imparted by providing a large number of protrusions on the backing material.

However, since the anti-slip layer made of synthetic resin or rubber in this conventional floor mat for automobiles is as heavy as 1,200-1,500 g per 1 m ² , the fuel efficiency of the automobile becomes worse when it is placed in the automobile compartment, and as a result As a result, a great load is placed on the environment. In addition, because it is difficult to separate the surface material and the backing material of used floor mats, they must be incinerated or disposed as industrial waste. However, incineration may generate harmful gases. In addition, in the case of disposal as industrial waste, the place is limited, and even if it can be disposed of, it causes a heavy pollution on the environment in various forms such as generating water pollution.

Further, this conventional automobile floor mat is made of synthetic resin or rubber, and has a protrusion on the back surface. When the conventional automobile floor mat is placed on a tufted carpet or needle punched carpet, Then, when a person stepped in, the protrusions got stuck in the pile and worked to stop slipping, but in recent years, high quality is required for the appearance quality of automobile interior materials, the above-mentioned tufted carpet, or Since the needle punch carpet has become a high-density product using thin threads, the protrusions have become difficult to bite. For this reason, an automobile floor mat made of synthetic resin or rubber is easy to slip, and when the automobile floor mat starts to slide, the contact area with the tufted carpet or needle punched carpet placed on the floor becomes unsatisfactory. Since it tends to be only the apex of the protrusion, and the contact area is reduced on the contrary, the promotion of slipping may lead to an accident.

On the other hand, in recent years, quietness in automobile interiors has been highly demanded, and various attempts have been made. One of them is improvement of the sound absorption effect in the automobile floor mat itself. However, in the automobile floor mat having the above-described conventional structure, a resin layer is provided on the back surface side, and this resin layer absorbs sound although it has a characteristic of reflecting sound from outside the vehicle. The characteristics are low. Therefore, it does not contribute much to the quietness in the interior of an automobile.
Japanese Examined Patent Publication No. 4-856

The present invention has been made in order to solve the above-mentioned problems, 1. Weight that imposes load on the environment, 2. Easiness of slip that leads to an accident, 3. Sound absorption that impairs quietness in an automobile interior. Therefore, it is an object to provide an automobile floor mat that has excellent anti-slip properties, excellent sound absorption, and is environmentally friendly.

In order to achieve the above object, the present invention provides the following means.

[1] In an automobile floor mat comprising an upper carpet, an anti-slip layer, and an adhesive layer, the anti-slip layer is composed of a lightweight carpet having a weight of 400 g / m ² or less, and the pile surface of each carpet is the outer surface. An automotive floor mat characterized by being bonded with an adhesive layer.

[2] The automobile according to the above item [1], wherein the carpet constituting the anti-slip layer is made of a polyester filament yarn having a single yarn fineness of 20 to 60 dtex, and the carpet pile length is 5 mm or less. Floor mat for use.

[3] The adhesive layer is a polyethylene resin film of 100 to 200 g / m ² , and the air permeability in the thickness direction of the entire automobile floor mat is 1 to 50 (cm ³ / cm ² · sec). The floor mat for an automobile according to [1] or [2], which is characterized in that it is characterized by the following.

In this specification, “air permeability” is the air permeability measured by the A method of 827.1 of JISL 1096-1999.

According to the invention of [1], the automobile floor mat of the present invention uses a lightweight carpet having a weight of 400 g / m ² or less made of fibers in place of a synthetic resin or rubber having a heavy weight in the anti-slip layer. Thus, the floor mat for an automobile can be made much lighter than the conventional floor mat. It is a floor mat for automobiles that does not deteriorate the fuel consumption of the automobile and has a low environmental impact.

According to the invention of [2], the single yarn fineness of the carpet pile of the non-slip layer constituting the automobile floor mat of the present invention is set to a thick yarn of 20 to 60 dtex, and the length of the carpet pile is 5 mm. By the following, the carpet floor of the anti-slip layer is caught on the fibers constituting the tufted carpet and needle punched carpet provided in advance on the automobile floor, and the friction resistance is increased and the anti-slip property is improved. Become a mat.

According to the invention of [3], by using a polyethylene resin film of 100 to 200 g / m ² as the adhesive layer constituting the automobile floor mat of the present invention, the adhesive layer exhibits sufficient adhesiveness, The air permeability in the thickness direction of the entire automobile floor mat can be ensured to 1 to 50 (cm ³ / cm ² · sec). As a result, the automobile floor mat of the present invention exhibits excellent sound absorption, and can provide quietness in the automobile compartment. In addition, since a polyethylene resin film is used as the adhesive layer, when an automobile floor mat is incinerated, no harmful gas is generated, so that the automobile floor mat is suitable for the environment.

Furthermore, by making the upper layer carpet and the fibers constituting the anti-slip layer carpet into recyclable polyester fibers, most of the floor mats for automobiles can be reused, and for automobiles with less environmental impact. It becomes a floor mat.

An embodiment of an automobile floor mat according to the present invention will be described below with reference to the drawings. The automobile floor mat of the present embodiment is an automobile floor mat that is used by being placed on a tufted carpet or a needle punched carpet previously laid on the floor of the automobile. FIG. 1 is a schematic cross-sectional view showing an enlarged part of the automobile floor mat of the present embodiment. (1) is an upper carpet, (2) is an anti-slip layer carpet, (3) is an upper carpet pile, (4) is an anti-slip carpet, (5) (9) is a polyester nonwoven fabric, (6) ( 8) is a latex layer, and (7) is an adhesive layer.

In the present embodiment, as an aspect of the upper-layer carpet (1), for example, tufted carpet, tsutsutsu, hook carpet, Wilton carpet, Akisminster carpet and the like can be used. Carpet is preferred.

In order to prevent the fibers from falling off in the upper carpet (1), a latex layer (6) such as styrene-butadiene rubber is provided on the lower surface of the upper carpet (1) to fix the fibers and prevent the pile from coming off. . However, the air permeability in the thickness direction of the upper carpet (1) after applying the latex needs to be set in the range of 1 to 50 (cm ³ / cm ² · sec).

In the present embodiment, as the carpet (2) of the anti-slip layer, for example, tufted carpet, tsutsutsu, hook carpet, Wilton carpet, Akisminster carpet and the like can be used. To tufted carpets are preferred.

Polyester filament yarn is used as the carpet pile (4) of the anti-slip layer, and a lightweight carpet having a weight of 400 g / m ² or less is formed. A more preferable weight is 300 to 400 / m ² .

The carpet pile (4) of the anti-slip layer is a yarn having a single yarn fineness of 20 to 60 dtex, and the pile length is 5 mm or less. Combined with the effect of the thickness and the shortness of the fibers constituting the pile, the carpet pile (4) of the anti-slip layer becomes a rigid raised state, and the automobile floor mat of the present invention is applied to the floor of the automobile. When the anti-slip layer carpet (2) is placed on the tufted carpet or needle punch carpet provided in advance so that the anti-slip layer carpet (2) is in contact, the tip of the pile fiber is caught by the pile constituting the tufted carpet or needle punch carpet. As a result, the anti-slip property is improved as a result of the increased frictional resistance. More preferable single yarn fineness is 40 to 60 dtex, and the pile length is 3 to 5 mm.

Further, the carpet pile (4) of the anti-slip layer is constituted by a cut pile. By cutting the tip of the pile, the area of contact with the tufted carpet and needle punch carpet provided in advance on the floor of the automobile is increased, and a pile having a good anti-slip property is formed.

In order to prevent the fibers from falling off the anti-slip layer carpet (2), a latex layer (8) such as styrene-butadiene rubber is provided on the lower surface of the anti-slip layer carpet (2) to fix the fibers and prevent the pile from coming off. To prevent. However, the air permeability in the thickness direction of the upper carpet (1) after applying the latex needs to be set in the range of 1 to 50 (cm ³ / cm ² · sec).

Furthermore, in this embodiment, the floor mat for an automobile of the present invention is incinerated at the time of disposal by using both polyester filament yarns as the fibers constituting the upper carpet (1) and the anti-slip carpet (2). No harmful gases are generated during the process. Further, if recycled polyester is used for the polyester filament yarns used for the upper carpet (1) and the anti-slip carpet (2), it becomes a car floor mat that further considers the environment.

In this embodiment, the integration of the upper carpet (1) and the non-slip layer carpet (2) adversely affects the fibers constituting the upper carpet (1) and the non-slip layer carpet (2) by the T-die extruder. A polyethylene resin film (7) that melts at a temperature that does not affect the above is integrated between the upper carpet (1) and the anti-slip carpet (2) by extrusion pressure cooling. The coating amount of the polyethylene resin film (7) is 100 to 200 g / m ² . As a result, the air permeability in the thickness direction of the entire automobile floor mat can be secured to 1 to 50 (cm ³ / cm ² · sec). As a result, the automobile floor mat of the present invention exhibits excellent sound absorption, and can provide quietness in the automobile compartment. As for the application quantity of the said polyethylene resin film (7), 150-200 g / m < ² > is preferable. Further, as the processing machine for bonding, a T-die type extruder is preferable because a relatively thin resin layer having stable air permeability can be formed.

Moreover, as a method for integrating the upper carpet (1) and the anti-slip carpet (2), heat melting is performed at a temperature that does not adversely affect the fibers constituting the upper carpet (1) and the anti-slip carpet (2). It is necessary to dispose the sheet between the upper carpet (1) and the anti-slip carpet (2) and to perform heat treatment at a temperature at which only the hot melt sheet can be fused.

When the automotive floor mat is incinerated, the heat-melting sheet to be used is preferably made of a polyolefin-based resin such as polyethylene that does not generate harmful gases.

If the upper carpet (1) and the anti-slip carpet (2) are integrated, the peripheral edge may be unsightly or the fibers may fall off. It is preferable to cover the peripheral edge portion by (overlock processing) or to cover the peripheral edge portion by edging processing (tape lock processing) with a cloth or resin tape. The yarn used for overlock processing is preferably nylon, polyester, polypropylene, or recycled polyester. The tape used for tape lock processing is nylon resin, polyester resin, polyolefin resin, or recycled polyester. By using the resin, it becomes an automobile floor mat suitable for the environment.

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

(Example 1) As an upper layer carpet, a non-woven fabric (weight: 100 g / m ² ) made of polyester fibers with a polyester yarn having a fineness of 2400 dtex composed of filaments having a single yarn fineness of 40 dtex using a tufting cut pile machine. 1/10 gauge (width: 39 / 10cm), 30 stitches (vertical density: 30 / 10cm), pile length 8mm, tufted carpet with a pile pile (pile weight: 600g) / M ² ) was prepared. A styrene-butadiene rubber latex having a dry mass of 100 g / m ² was applied to the back surface of the carpet in order to prevent the filament yarn from falling off.

On the other hand, a polyester yarn having a fineness of 2400 dtex composed of filaments having a single yarn fineness of 40 dtex as a carpet of the anti-slip layer 2 is woven with a nonwoven fabric (weight: 100 g / m ²⁾ using a tufting cut pile machine. ) 1/10 gauge (horizontal density: 39 pieces / 10 cm), 30 stitches (vertical density: 30 pieces / 10 cm), 3 mm pile length, tufted with a pile length of 3 mm. A Ted carpet (weight: 300 g / m ² ) was prepared. A styrene-butadiene rubber latex having a dry mass of 100 g / m ² was applied to the back surface of the carpet in order to prevent the filament yarn from falling off.

Next, a polyethylene resin film extruded from a T-die extruder is supplied between the upper layer carpet (Latex coating side) and the anti-slip layer carpet (Latex coating side), and the upper layer is interposed through the polyethylene resin film. The carpet and anti-slip layer were integrated. The coating amount of this polyethylene resin film was 200 g / m ² . Next, this integrated product was cut into the size of an automobile floor mat, and overlocked with a yarn made of polyester, to produce an automobile floor mat having a weight of 1,500 g / m ² . The air permeability in the thickness direction of this automobile floor mat was 32.2 (cm ³ / cm ² · sec).

(Example 2) In the same manner as in Example 1 except that a filament yarn made of polyester yarn having a fineness of 2400 dtex composed of a filament having a single yarn fineness of 20 dtex was used in the carpet of the non-slip layer, an automobile A floor mat was manufactured. The air permeability in the thickness direction of this automobile floor mat was 26.9 (cm ³ / cm ² · sec).

(Example 3) In the same manner as in Example 1 except that a filament yarn made of polyester yarn having a fineness of 2400 dtex composed of filaments having a single yarn fineness of 60 dtex was used for the carpet of the non-slip layer. A floor mat was manufactured. The air permeability in the thickness direction of this automobile floor mat was 22.6 (cm ³ / cm ² · sec).

(Comparative Example 1) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a sheet of 1,700 g / m ^{2 made} of a synthetic resin was used in place of the carpet as the anti-slip layer. The air permeability in the thickness direction of this automobile floor mat was 0.0 (cm ³ / cm ² · sec).

(Comparative Example 2) In the same manner as in Example 1, except that a filament yarn made of polyester yarn having a fineness of 2400 dtex composed of filaments having a single yarn fineness of 10 dtex was used in the carpet of the non-slip layer. A floor mat was manufactured. The air permeability in the thickness direction of this automobile floor mat was 43.3 (cm ³ / cm ² · sec).

(Comparative Example 3) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that the pile length of the anti-slip layer carpet was 10 mm. The air permeability in the thickness direction of this automobile floor mat was 40.1 (cm ³ / cm ² · sec).

(Comparative Example 4) A car floor mat was produced in the same manner as in Example 1 except that the amount of the polyethylene resin film in the adhesive layer was 500 g / m ² . The air permeability in the thickness direction of this automobile floor mat was 2.5 (cm ³ / cm ² · sec).

Each of the automobile floor mats obtained as described above was examined for anti-slip property and sound absorption property based on the following evaluation method. The results are shown in the table.

(Anti-slip test) Each of the automobile floor mats (100 mm × 140 mm) of Examples 1 to 3 and Comparative Examples 1 to 4 was placed on a general needle punch carpet laid on the automobile floor. The mat was placed in contact with the backing material. Next, with the load of 1 kg applied on the surface material of the automotive floor mat, the automotive floor mat is pulled horizontally at a pulling speed of 100 mm / min with respect to the surface of the needle punched nonwoven fabric to slide the automotive floor mat. The static frictional resistance force when measured was measured. The results are shown in Table 1. The static frictional resistance is an average value of values measured five times. Assuming the case where an automobile floor mat is arranged in an actual automobile room, it was determined that the floor mat for an automobile had excellent anti-slip property and did not slip at a static friction resistance of 25 N or more.

(Sound absorption characteristic test) The sound absorption coefficient was measured according to the normal incident sound absorption coefficient measurement method of ASTM E1050.

(Silence Evaluation Method) The above sound absorption characteristics were evaluated by evaluating whether the sound absorption characteristics were 0.1 or more at both frequencies of 1000 Hz and 2000 Hz, and the sound absorption coefficient was 0.3 or more. Those with a sound absorption rate of less than 0.1 were evaluated as rejected with a quietness of “x”.

As is clear from Table 1, it was found that the automobile floor mats of the present invention shown in Examples 1 to 3 have high static friction resistance and are difficult to slip. Moreover, it turned out that the floor mat for motor vehicles shown in Examples 1-3 and Comparative Examples 2-3 is a floor mat for motor vehicles excellent in sound absorption performance.

On the other hand, Comparative Example 1 is a very heavy automobile floor mat, Comparative Example 2 and Comparative Example 3 cannot ensure slip resistance, and Comparative Example 1 and Comparative Example 4 provide good sound absorption performance. I couldn't.

It is a schematic sectional drawing of the carpet for vehicles concerning one Embodiment of this invention.

Explanation of symbols

1 ... upper carpet 2 ... lower carpet 3 ... upper carpet pile 4 ... lower carpet pile 5, 9 ... polyester nonwoven fabric 6, 8 ... latex layer 7 ... adhesive resin layer

Claims (3)

In an automotive floor mat comprising an upper carpet, an anti-slip layer, and an adhesive layer, the anti-slip layer is composed of a lightweight carpet having a weight of 400 g / m ² or less, and an adhesive layer with the pile surface of each carpet as the outer surface. Laminated car floor mats. The automobile floor mat according to claim 1, wherein a polyester filament yarn having a single yarn fineness of 20 to 60 dtex is used for the carpet constituting the anti-slip layer, and the carpet pile length is a cut pile of 5 mm or less. The adhesive layer is a polyethylene resin film of 100 to 200 g / m ² , and the air permeability in the thickness direction of the entire automobile floor mat is 1 to 50 (cm ³ / cm ² · sec). The floor mat for automobiles according to claim 1 or 2.

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