JP2008174050A - Lamination structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve problems of a lamination structure composed of a felt material and a padding material to be layered beneath a carpet since a gap occurs between the felt material and the padding material and the bonded padding material makes recovery for recycling difficult. <P>SOLUTION: In an arrangement structure for the lamination structure under a floor carpet laid on a floor panel in a vehicle cabin, the lamination structure is constructed of a flexible felt material and a padding material formed of a material harder than the felt material. At least two slits separated from each other are formed in the felt material. Using an area between the two slits as an installation area for the padding material, the padding material is held between the felt material and the carpet. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an arrangement structure of a laminated structure under a carpet laid on a floor surface of an automobile.

Conventionally, a floor carpet is laid on a floor panel in an automobile interior. This floor carpet is based on tufted carpets and needle punched carpets, and is backed with a thermoplastic resin backing or a fiber layer containing thermoplastic resin fibers, and is molded and laid in a shape along the floor panel at the laying position. .
In addition, a laminated structure is generally disposed on the back surface of the floor carpet. One of the purposes for disposing the laminated structure is to substantially level the automobile floor surface. Since the floor panel usually has a concavo-convex shape, it is not preferable that the concavo-convex shape appears remarkably at the feet of the occupant because it leads to deterioration of riding comfort and the like. Therefore, this problem is solved by arranging a laminated structure along the unevenness of the floor panel on the back surface of the floor carpet. Further, by providing this laminated structure, it becomes possible to provide cushioning properties, and further, noise that enters the automobile room from the floor panel direction may be reduced. In general, the laminated structure is disposed on the carpet back surface for the above purpose.
As a general laminated structure, a combination of a flexible felt material and a raising material made of a material harder than the felt material (generally urethane chips and bead foam moldings) is used. The main role of both is to improve the cushioning and sound absorption of the felt material, and to raise the level of the floor surface by filling the unevenness of the floor panel.
As for the size of the laminated structure, a felt material having a thickness of about 5 to 30 mm and a raising material having a thickness of about 10 to 50 mm are generally used.
As the arrangement structure of the laminated structure, it is preferable that both the felt material and the raising material are integrated on the carpet back surface. If one or both of the felt material and the raising material is separate from the floor carpet, there is a problem that the number of processes increases in the assembly work to the automobile in addition to the reduction in transportation efficiency. In order to solve this problem, it is preferable that both the felt material and the raising material are integrated on the back surface of the carpet as described above.
An arrangement structure in which both the felt material and the raising material are integrated on the carpet back surface is an arrangement structure in which the raising material is first attached to the carpet back surface, and then the felt material is attached so as to cover the raising material. Moreover, the arrangement | positioning structure which affixes a felt material on the carpet back surface and affixes a raising material on the felt material affixed on the carpet back surface is also mentioned.

There are the following as problems of the above prior art.
When adopting a configuration in which a raising material is attached to the back surface of the carpet and the raising material is covered with the felt material, it is difficult to completely fit the felt material to the outer shape of the raising material. Therefore, a gap is generated between the two, and a sharp shape does not appear.

  Further, when a gap is generated between the felt material and the raising material, sound waves that are not absorbed by the felt material reach the passenger compartment through the gap.

Further, since both the carpet and the felt material are made of thermoplastic fibers, they can be recycled and recovered at the same time. However, as described above, the raising material is made of urethane chips or bead foam moldings, and therefore must be separated from the carpet and the felt material when recycled. However, if the raising material is attached to the carpet or felt material, it is difficult to separate and collect the raising material.
The present invention solves the above-described problems of the prior art.

  An arrangement structure of a laminated structure 1 under a floor carpet 10 laid on a floor panel in an automobile interior, wherein the seat structure is made up of a flexible felt material 20 and a material harder than the felt material 20 The felt material 20 is provided with at least two mutually spaced slits 21, 21 ′, and the raising material 30 is interposed between the two slits 21, 21 ′. The stacking structure 22 under the automobile floor carpet 10 is sandwiched between the felt material 20 and the carpet 10 as the mounting area 22 for the raising material 30.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing a first embodiment of a laminated structure 1 according to the present invention. The laminated structure 1 includes a flexible felt material 20 and a raising material 30 made of a material harder than the felt material 20, and is disposed under a floor carpet (not shown) of an automobile.

As the felt material 20 suitable for the present invention, a known felt material such as a synthetic felt made of polyester fiber, a mixed cotton felt, or a resin felt can be used. The thickness of the felt material is about 5 to 30 mm, and the size in the surface direction is larger than that of the raising material 30. The outer shape of the felt material 20 is equal to or smaller than the outer shape of the floor carpet 10. Further, a plurality of divided laminated structures of felt material and raising material may be arranged in parallel on the back surface of one floor carpet 10.
The felt material 20 can be bent easily by bending it by hand, and the thickness of the part will be reduced if force is applied in the direction perpendicular to the surface. If it is suitable and lacks flexibility, it is difficult to stretch the raised material 30 for placement, and the followability to the raised material 30 deteriorates.

  The raising material 30 suitable for the present invention is made of a material harder than the felt material 20, and a known raising material such as a bead foam molded body or a urethane chip molded body can be used. The thickness of the raising material is about 10 to 50 mm, and a thick plate is more suitable than the thickness of the felt material. The size in the plane direction is a size that is essentially contained inside the felt material 20 to be laminated, and the outer shape is preferably close to a square, but is set according to the uneven shape of the floor panel. For ease of mounting on the felt material 20, it is preferable to round the rectangular corners slightly as shown in the figure.

  Further, it is suitable that the degree of hardness of the raising material 30 is at least harder than that of the felt material 20 and has a hardness that does not cause conspicuous dents in the raising material 30 even when the weight is applied to the passenger's feet.

  In the felt material 20 of the present invention, at least two slits 21 and 21 ′ are formed, and the space between the slits 21 and 21 ′ is formed as a placement area 22 for the raising material 30. In the embodiment of FIG. 1, two slits 21 and 21 'are formed substantially in parallel at a predetermined interval.

  In FIG. 1, two slits are formed, and the length, shape, number, and interval are appropriately determined according to the form of the raising material 30 to be placed. As a preferred embodiment, when two slits are formed, the spacing is substantially equal to or slightly larger than the width of the raised material 30 to be placed, and the raised material is inserted between the slits. Moreover, the length of the slit is preferably longer than the length of the raising material 30 to be placed by about the thickness of the raising material 30.

A method for laminating the felt material 20 and the raising material 30 will be described below with reference to FIG. In the embodiment of FIG. 1, a substantially rectangular parallelepiped raising material 30 (thickness 15 mm, width 50 mm, length 110 mm) is laminated in the same manner as a substantially rectangular felt material 20 (thickness 10 mm, width 120 mm, length 180 mm).
In the felt material 20, two slits 21 and 21 'having a length of 110 mm are formed substantially in parallel with an interval of 50 mm.

Between the two slits 21, 21 ′ formed in the felt material 20, the placing area 22 is placed, and the raising material 30 is placed so as to fit in the placing area 22, and the raising material 30 is placed below the felt material 20. Until the top surface 32, which is the top surface of the raising material 30, and the top surface 23, which is the top surface of the felt material 20, are at the same height. At this time, the slits 21 and 21 'of the felt material 20 are opened up and down, and the mounting area 22 is extended by the amount pushed by the raising material 30, and finally viewed in the length direction as shown in FIG. There is an inclined portion 24 in the front and rear, and the space between them is bent into a flat portion, so that the raising material 30 can be accommodated in the placement area 22 of the felt material 30.
In this situation, the mounting area 22 deflected downward has a slight force to return to its original shape due to its self-shape-retaining characteristics, and as a result, the raising material 30 is raised above the upper part 32 of the felt material. However, the urging force is not generated so that the raising member 30 is immediately jumped up.
The laminated structure 1 loaded in this manner has its upper surface (upper part 32 and top surface 23) adhered to the rear surface of an automotive floor carpet (not shown). As a result, the raising material 30 is composed of the rear surface of the floor carpet and the felt material. It is sandwiched between 20 placement areas 22.

Adhesion of the laminated structure 1 to the back surface of the floor carpet is performed by applying an adhesive to both the upper part 32 of the felt material 20 and the top surface 23 of the raising material 30 or only the upper part 32 of the felt material 20. Can be glued to the back of the floor carpet. Alternatively, a low-melting fiber or thermoplastic resin backing is applied to the back of the floor carpet in advance, and the low-melting fiber or thermoplastic resin backing is heat plasticized to attach the felt material 20 or the raising material 30 to an anchor. It is also possible to wear it.
At this time, even if the adhesive is not applied to the upper portion 32 of the raising material 30 and the adhesive is applied only to the top surface 23 of the felt material 20, the raising material 30 is surrounded by the slits 21, 21 of the felt material 20. Since the lower portion is supported by the inner wall 26 that appears and is pushed upward by the placement area 22, there is no possibility that the raising material 30 falls off the placement area 22. On the other hand, for recycling, it is possible to break or stretch part of the felt material 20, and to remove the raising material 30 from the felt material 20. The fiber floor carpet and felt material 20, and the resin material It is easy to separate, collect and recycle the raising material 30.

  3 and 4 are cross-sectional views of the laminated structure 1 shown in FIG. 1, FIG. 3 is a cross-sectional view taken along line AA in FIG. 1, and FIG. 4 is a cross-sectional view taken along line BB in FIG. Further, a floor carpet 10 (not shown) is additionally shown in FIG.

FIG. 3 is a cross-sectional view taken along the line AA of FIG. 1, and the raising material 30 is sandwiched between the inner walls 26 of the felt material 20 with its side surfaces 33 without any gaps. The upper portion 32 is sandwiched between the back surface of the floor carpet 10 and the lower surface is sandwiched between the upper surface of the placement area 22 of the felt material 20 without a gap.
In this sectional view, there is no gap between the felt material 20 and the raising material 30. Therefore, it is shown that sound leakage from the floor panel direction hardly occurs. Further, a sound absorbing hole may be formed on the side surface 33 of the raising material 30 that can be seen from the felt material 20 to enhance sound absorption.

4 is a cross-sectional view taken along the line BB of FIG. 1. The raising member 30 is sandwiched between the upper surface of the floor carpet 10 and the lower portion of the felt material 20 on the upper surface of the mounting area 22 without any gaps. A wedge-shaped gap 40 is opened between the inclined portion 24 of the mounting area 22.
The gap 40 generated between the felt material 20 and the raising material 30 is small, but there is a possibility that sound that has not been absorbed by the felt material 20 reaches the passenger compartment. In order to solve this problem, it is effective to take the laminated structure 1 shown in FIG.

  FIG. 2 shows a preferred embodiment with respect to the above-described problem, and is a view showing the raising material 30 and the felt material 20 in a perspective view before being assembled to each other.

In this embodiment, the convex shape 31 is extended from the side surface of the raising material 30, and this is formed on the front and back of the raising material 30.
On the other hand, an opening 25 is formed in the inclined portion 24 of the felt material 20. The opening 25 can accommodate a convex shape 31 formed in the raising material 30. Therefore, the opening 25 is formed at a position where the convex shape 31 faces when the upper portion 32 of the raising material 30 and the top surface 23 of the felt material 20 are pushed into the same height. ing.
The size of the convex shape 31 is not limited. However, when the length is longer than the thickness of the felt material 20, the work is troublesome when the raising material 30 is pushed into the felt material 20, so the felt material A thickness of about 20 is suitable.

  As a method of placing the raising material 30, a method of placing the raising material 30 on the placement area 22 between the slits 21 and 21 'of the felt material 20 and pushing it downward is conceivable. Since the felt material 20 is made of a material that can be bent by the raising material 30, the opening 25 or the inclined portion 24 is bent downward by pushing the raising material 30 into the placement area 22, and the convex shape 31 is the opening 25. A force to return to the original shape acts on a part of the felt material 20 that has been bent when positioned at the position, and the convex shape 31 can be accommodated in the opening 25. Further, the raising material is inclined obliquely with respect to the placement area 22, and one of the two formed convex shapes 31 is stored in the corresponding opening 25, and then the raising material 30 is placed in the placement area 22 It is also possible to consider means for bending into the opening 25 corresponding to the convex shape 31 by bending around the inclined portion 24 or the opening 25.

  FIG. 5 shows a laminated structure 1 in which the felt material 20 and the raising material 30 shown in FIG.

From FIG. 5, it is clear that the gap 40 in FIG. 4 is partially filled with the convex shape 31 in FIG. In this way, by forming the convex shape 31, it is possible to fill a part of the gap 40 between the raising material 30 and the inclined portion 24 of the felt material 20, and to improve the sound performance.
Further, this convex shape 31 prevents the lifting material 30 from moving upward due to the self-shape retaining force of the felt material 20 that is generated when the lifting material 30 is pushed into the placement area 22 of the felt material 20. Can do.

FIG. 6 shows a modified embodiment of the present invention.
In FIG. 6 a), the slits 21 and 21 ′ are curved. Further, along with this, the outer shape of the raising material along the slit is also curved. As this effect, an effect of preventing the raising material from shifting in the horizontal direction in the figure can be obtained.

  In FIG. 6 b), the shape of the mounting area constituted by the slits 21 and 21 ′ is substantially a cross, and is shaped like a rectangular convex portion. This shape prevents the raising material from moving in the horizontal direction.

  In FIG. 6 c), the shapes of the slits 21 and 21 ′ are the same as in b), but the size and shape of the raising material 30 are different. In this state, it is possible to adopt a configuration in which the inclined portion 24 of the felt material 20 and the side surface 33 which is a portion where the raising material 30 is in contact are more aligned. Further, like the other embodiments, the raising member 30 can be prevented from moving in the horizontal direction.

  In FIG. 6 d), three slits 21, 21 ′, 21 ″ are formed in parallel. In addition, raising materials of different sizes are accommodated between each. The raising materials of different sizes are adjacent to each other. This makes it possible to form a stepped shape on the lower surface of the laminated structure, which is the case when the unevenness of the floor panel is stepped. However, it is possible to provide a laminated structure along the floor panel.

FIG. 7 shows a modification of the shape of the raising material.
In FIG. 7 a), in addition to forming the convex shape 31 at a position opposite to the inclined portion 24, the felt material 20 in contact with the carpet and the surface on which the raising material 30 is placed in the placement area 22. A convex portion 34 is provided on the side surface 33 so as to fit in an opening formed between the rear surface and the rear surface. The state where this is actually laminated with felt material is described in b).

  As can be seen in FIG. 7 b), by implementing this shape, it is possible to more effectively prevent the raising material 30 from moving up and down than in a). Alternatively, only the convex portion 34 may be formed without forming the convex shape 31 described in claim 3.

  In FIG. 7 c, a protrusion 34 ′ is formed on the bottom surface of the raising material 30. In this case, it is preferable to provide a concave portion (not shown) in which the convex portion 34 ′ can be accommodated at a position opposite to the convex portion in the placement area 22 of the felt material 20. By combining the convex portion 34 'and the concave portion, the raising member 30 can be prevented from moving in the horizontal direction.

  In FIG. 7 d), the shape of the tip of the convex shape 31 ′ provided in the front-rear direction of the raising member 30 is different from the above shape. This convex shape 31 ′ is a shape along the inclined portion 24 of the felt material 20 when viewed from the width direction of the raising material 30. As a result, the convex shape 31 ′ does not protrude from the inclined portion 24 after the raising material 30 and the felt material 20 are assembled.

1 is a perspective view of a first embodiment of the present invention. Perspective view of the second embodiment of the present invention AA sectional view of FIG. BB sectional view of FIG. BB sectional view of FIG. 1 in the second embodiment Modified example of felt material Modification example of raising material

Explanation of symbols

1: Laminated structure 10: Carpet 20: Felt material 21, 21 ′, 21 ″: Slit 22: Placement area 23: Top surface 24: Inclined portion 25: Opening 26: Inner wall 30: Raising material 31, 31 ′: Convex shape 32: Upper part 33: Side surface 34, 34 ': Convex part 40: Gap

Claims (3)

A laminated structure 1 under a floor carpet 10 laid on an indoor floor panel of an automobile,
The laminated structure 1 comprises a flexible felt material 20 and a raising material 30 made of a material harder than the felt material 20,
The felt material 20 is provided with at least two slits 21, 21 ′,
The raising member 30 is sandwiched between the felt material 20 and the carpet 10 with the space 21 between the slits 21 and 21 ′ of the felt material 20 as a placement area 22.   The laminated structure according to claim 1, wherein the raised material (30) is provided with a convex shape (31) extending from the main body of the raised material (30), and the convex shape (31) is recessed from the felt material (20).   The convex shape 31 extended from the said raising material 30 main body is provided, and the opening 25 which accommodates the said convex shape 31 is provided in the said felt material 20, The Claim 1 or Claim 2 characterized by the above-mentioned. Laminated structure.

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