JP2009137465A - Floor mat for automobile and manufacturing method of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat for an automobile, in which a front sheet and a back sheet are strongly integrated together without generating a rugged pattern even if the front sheet and the back sheet are integrated by a porous sheet having perforations, and provide a manufacturing method of the same. <P>SOLUTION: The floor mat is formed such that a front sheet, a porous sheet having perforations, and a back sheet are laminated in this order, and the front and back sheets are integrated by melting of the porous sheet. The porous sheet has a thermoplastic elastomer as a principle component, and contains an adhesive agent. Such a floor mat can be manufactured by laminating the front sheet, the porous sheet having the perforations, having the thermoplastic elastomer as a principle component, and containing the adhesive agent, and the back sheet in this order, and the laminated sheet is then pressed at 29 N/cm to 245 N/cm in a state in which the porous sheet is melted. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an automobile floor mat and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, a floor mat is laid on a floor carpet in order to prevent dirt, sand, and the like adhering to shoes and the like from adhering to the floor carpet in the automobile and soiling the floor carpet in the automobile.

  By the way, in the current car, a car navigation system using voice has started to spread, and interest in quietness in the car is increasing. As one of the methods for improving the quietness in the vehicle, there is a method of improving the sound absorbing property in order to reduce the sound that enters the vehicle. For this reason, sound absorbing properties are actively applied to interior materials including floor mats.

  For example, an extruded sheet having through-holes with an apparent specific gravity of 0.2 to 0.9 obtained by extrusion foam molding of an elastomer composition containing a foaming agent with respect to 100 parts by weight of a thermoplastic elastomer, and a carpet base A sound-absorbing mat in which a cloth and a base material layer are laminated has been proposed (Patent Document 1).

Japanese Patent Laying-Open No. 2005-2187 (claims, paragraph number 0061, etc.)

  The extruded sheet having a through hole disclosed in Patent Document 1 has a through hole over the entire sheet, and this through hole has an effect of easily passing or absorbing noise. When a base layer of a sound absorbing material such as the above is bonded, the noise can be absorbed by the base layer of the sound absorbing material by passing through the through-hole without being reflected by the extruded sheet.

  An elastomer containing 0.1 to 20 parts by weight of a foaming agent with respect to 100 parts by weight of a thermoplastic elastomer as a method for producing a sound-absorbing mat in which a carpet base fabric and a base material layer are bonded via such an extruded sheet The composition is extruded and foam-molded by an extruder having a cylinder temperature of 150 to 170 ° C. and a die temperature of 110 to 150 ° C., and a tufted carpet base fabric or a nonwoven fabric carpet base fabric and a base material layer are immediately after extrusion molding. There has been proposed a method of bonding by take-up roll lamination pressure bonding. When a sound-absorbing mat is manufactured by such roll lamination pressure bonding, since an extruded sheet having through holes obtained by extrusion foam molding has large through holes, an uneven pattern occurs when viewed from the substrate layer side. There was a problem that the designability was impaired. That is, the carpet base fabric and the base material layer are bonded to each other portion of the extruded sheet other than the through-holes, but the carpet base fabric and the base material layer are not bonded to each other and float in the through-hole portions of the extruded sheet. Therefore, there is a problem in that an uneven pattern is generated in which the bonded portion becomes a concave portion and the unbonded portion becomes a convex portion.

  Therefore, the present inventor makes the difference between the part adhered by the extruded sheet and the part not adhered less noticeable when the pressure at the time of producing the sound-absorbing mat is reduced by roll lamination pressure bonding, and the uneven pattern is not generated. The pressure was actually lowered. In this case, as expected, the concavo-convex pattern did not occur, but the adhesive force between the carpet base fabric or the nonwoven fabric carpet base fabric and the base material layer, which is the original action of the extruded sheet, is weak and easily peeled off. A new problem has occurred.

  The present invention has been made in view of such a situation, and even when the topsheet and the backsheet are integrated by a porous sheet having a through hole, the topsheet and An object of the present invention is to provide an automotive floor mat firmly integrated with a back sheet and a method for manufacturing the same.

  The invention according to claim 1 of the present invention is an automobile floor mat in which a top sheet, a porous sheet having a through hole, and a back sheet are laminated in order, and are integrated by fusion of the porous sheet, The porous sheet has a thermoplastic elastomer as a main component and contains a tackifier.

  The invention according to claim 2 of the present invention is "the floor mat for an automobile according to claim 1, wherein the tackifier occupies 0.95 to 20 mass% of the porous sheet".

  According to a third aspect of the present invention, there is provided an automobile floor in which a top sheet, a porous sheet having a through hole, and a back sheet are laminated in order, and then the porous sheet is pressed and integrated in a molten state. A method for manufacturing a mat, comprising a thermoplastic elastomer as a main component as the porous sheet, a material containing a tackifier, and pressurizing at a pressure of 29 N / cm to 245 N / cm. A manufacturing method of a floor mat. "

  The invention according to claim 4 of the present invention is “the method for producing an automobile floor mat according to claim 3, wherein the tackifier occupies 0.95 to 20 mass% of the porous sheet”. is there.

  In the invention according to claim 1 of the present invention, since the porous sheet contains a tackifier, the top sheet and the back sheet can be firmly integrated even if a lower pressure than before is applied. It is a floor mat for automobiles that does not have an uneven pattern and is difficult to peel off the top sheet and the back sheet.

  In the invention according to claim 2 of the present invention, since the amount of the tackifier is 0.95 to 20 mass% of the porous sheet, the top sheet and the back sheet are firmly bonded even when a lower pressure is applied than before. Further, since the through holes of the porous sheet do not become too large, they are not cut when the porous sheet is formed.

  In the invention according to claim 3 of the present invention, since the porous sheet contains a tackifier, the top sheet and the back sheet can be firmly integrated even if a lower pressure than before is applied. There can be produced a floor mat for automobiles which has no uneven pattern and is difficult to peel off the top sheet and the back sheet.

  In the invention according to claim 4 of the present invention, since the amount of the tackifier is 0.95 to 20 mass% of the porous sheet, the top sheet and the back sheet can be strengthened even when a lower pressure is applied than before. In addition, since the through-holes of the porous sheet do not become too large, the automobile floor mat can be manufactured without cutting during the formation of the porous sheet.

  First, a method for producing an automobile floor mat of the present invention (hereinafter sometimes simply referred to as “mat”) will be described.

  First, a top sheet, a porous sheet having a through hole, and a back sheet are prepared. Since the surface sheet is a sheet that can be seen with eyes when a mat is laid, it is preferably made of a carpet having excellent decorativeness. Examples of the carpet include tufted carpet, needle punched carpet, Unicom, hook carpet, Wilton carpet, and Akisminster carpet.

  The back sheet is a sheet that comes into contact with the floor carpet when the mat is laid on the floor carpet in the automobile. Since this back sheet is preferably capable of exhibiting sound absorbing performance in addition to the sound absorbing performance of a porous sheet having through holes, which will be described later, a resin sheet in which through holes are formed by needle punched nonwoven fabric, foamed foam, needles, etc. And the like. In addition, as described above, since the back sheet is in contact with the floor carpet, it is preferable to exhibit an anti-slip action. Accordingly, (a) a part of the resin that protrudes on the contact surface of the needle punched nonwoven fabric with the floor carpet, (b) the contact surface side of the needle punched nonwoven fabric with the floor carpet is irradiated with flame, Some of the fibers are melted and then solidified to form a resin lump, (c) Concavities and convexities on the side of the foamed floor carpet that has open cells, (d) Needle punch It is preferable to use a non-woven fabric floor contact surface coated with an adhesive in the form of dots or fibers as the back sheet. Note that the back sheet need not be a single layer, and may be composed of two or more layers. In the case of two or more layers, the contact surface with the floor carpet is preferably composed of any one of the above (a) to (d).

  A porous sheet having a through-hole can integrate the above-mentioned top sheet and back sheet by fusing, and uses a thermoplastic elastomer as a main component and a tackifier. For example, the extrusion sheet | seat which has a through-hole disclosed by Unexamined-Japanese-Patent No. 2005-2187 can be used as a porous sheet which has a through-hole of this invention. More specifically, it is preferable that the thermoplastic elastomer contains 1,2-polybutadiene having a low melt viscosity and being easily foamed by an inorganic foaming agent. The 1,2-polybutadiene preferably has a 1,2-vinyl bond content of 70% or more. Further, 1,2-polybutadiene preferably has crystallinity, and preferably has a melting point of 50 to 130 ° C. 1,2-polybutadiene is a copolymer of conjugated dienes other than butadiene, such as 1,3-pentadiene, 1,3-butadiene derivatives substituted with higher alkyl groups, and 2-alkyl-substituted-1,3-butadiene. Also good. Further, the weight average molecular weight of 1,2-polybutadiene is preferably 10,000 to 5,000,000.

  In addition to 1,2-polybutadiene, thermoplastic elastomers include styrene-based thermoplastic elastomers, olefin-based thermoplastic elastomers, urethane-based thermoplastic elastomers, ester-based thermoplastic elastomers, amide-based thermoplastic elastomers, PVC-based thermoplastic elastomers, ion clusters. It may be a mixture of at least one type of thermoplastic elastomer, fluorine-based thermoplastic elastomer containing a fluororesin as a constraining block, natural rubber, and synthetic rubber. In addition to the thermoplastic elastomer, a thermoplastic resin may be included. In addition, inorganic fillers, softeners, mineral oil-based extenders, surfactants, bituminous products, flame retardants, antioxidants, lubricants, colorants, UV absorbers, heat stabilizers, anti-aging agents for thermoplastic elastomers Other additives such as processing aids, light resistance (weathering) agents, and antibacterial agents may be added.

  Through-holes can be formed in the thermoplastic elastomer, and the inorganic or organic foaming agent is 0.1 to 20 weights with respect to 100 parts by weight of the thermoplastic elastomer so that the porous sheet is excellent in sound absorbing performance. Some parts are mixed.

  The porous sheet of the present invention contains a tackifier in addition to the thermoplastic elastomer as described above. Due to the presence of this tackifier, the top sheet and the back sheet can be firmly integrated even if the pressure is low. As a result, even when viewed from the back sheet side, a concavo-convex pattern was not generated, and it was possible to manufacture a mat having excellent design properties. In addition, since the pressure at the time of integration can be reduced, the degree to which the back sheet is compressed is reduced, and the thickness of the back sheet is not reduced, so that it is possible to manufacture a mat that is unlikely to deteriorate the sound absorption performance by the back sheet. There are also secondary effects.

  Examples of the tackifier include coumarone resin (for example, Escron G-90 (manufactured by Nikko Chemical Co., Ltd.), Escron V-120 (manufactured by Nikko Chemical Co., Ltd.)), C5 resin (for example, Marcaretz). R-100AS (registered trademark, manufactured by Maruzen Petrochemical Co., Ltd.), Marcaretz R-100A (registered trademark, manufactured by Maruzen Petrochemical Co., Ltd.)), terpene polymer (for example, YS Resin PX1000, manufactured by Yasuhara Chemical Co., Ltd.) And aromatic-modified terpene polymers (for example, YS Resin TO105, manufactured by Yasuhara Chemical Co., Ltd.) and terpene phenol copolymers (for example, YS Polystar T, manufactured by Yasuhara Chemical Co., Ltd.). Such a tackifier preferably accounts for 0.95 to 20 mass% of the porous sheet. If it is less than 0.95 mass%, the integration of the topsheet and the backsheet with the porous sheet becomes insufficient and tends to be peeled off. Therefore, it is more preferably 2 mass% or more, and 4 mass% or more. More preferably. On the other hand, if it exceeds 20 mass%, the melt viscosity of the thermoplastic elastomer is lowered, the force of retaining the gas generated from the foaming agent in the thermoplastic elastomer is weakened, and the hole diameter of the through hole is very large during foam molding. It tends to be non-uniform, and the hole diameter of the through-holes of the porous sheet tends to be too large and tends to break. Therefore, it is more preferably 15 mass% or less, and it is 10 mass% or less. Is more preferable.

Such a porous sheet having a through-hole mainly composed of a thermoplastic elastomer is obtained by, for example, melting a thermoplastic elastomer at a temperature of 60 to 180 ° C., mixing a foaming agent and a tackifier, and extruding it. Obtainable. Since the porous sheet obtained in this way has a microporous structure due to foaming of the foaming agent, the porous sheet itself has sound absorption performance and also has through holes, so that sound is transmitted to the back sheet and sound absorption performance by the back sheet. Can be demonstrated. The porous sheet has an air permeability of 10 to 200 cm ³ / cm ² / sec. Is preferred. The air permeability is 10 cm ³ / cm ² / sec. If it is less than, the hole diameter of the through hole of the porous sheet is too small, the through hole is crushed at the time of fusion integration with the top sheet and / or the back sheet, there is no breathability, and a mat with poor sound absorption performance The air permeability is 200 cm ³ / cm ² / sec. This is because the hole diameter of the through hole of the porous sheet is too large, the fusion area with the top sheet and / or the back sheet is too small, and the fusion force tends to be weakened. A more preferable air permeability is 70 to 170 cm ³ / cm ² / sec. More preferable air permeability is 100 to 150 cm ³ / cm ² / sec. It is. This “air permeability” refers to the value of JIS L 1096 (6.27.1 A method (Fragile method)).

  Next, after the prepared front sheet, porous sheet having through-holes, and back sheet are laminated in this order, the porous sheet is pressed in a molten state, and is integrated by fusing the porous sheet. A mat can be manufactured. The state in which the porous sheet is melted may be formed by heating and melting the porous sheet obtained by extrusion molding, or may be a molten porous sheet extruded from a die. In terms of manufacturing, the latter is more reasonable.

  In addition, in this invention, there is no uneven | corrugated pattern when it sees from a back surface sheet side by performing the pressurization for integration at a pressure lower than conventional (294 N / cm) called pressure 29-245 N / cm, In addition, a mat having sufficient fusing power can be manufactured. The pressure is preferably 49 to 196 N / cm, more preferably 49 to 147 N / cm, and still more preferably 49 N / cm to 98 N / cm. The pressurization can be performed with, for example, a pair of rolls, a press machine, or the like. Further, the pressing may be performed in a long state in which the top sheet, the porous sheet having through holes, and the back sheet are laminated in this order, and then cut into a mat shape, or the top sheet and the through holes may be formed. The perforated sheet and the back sheet may be laminated in this order, cut into a mat shape, and then pressed.

  In the mat of the present invention, a top sheet, a porous sheet having a through-hole, and a back sheet are laminated in order, and are integrated by fusing the porous sheets. Since this porous sheet is mainly composed of a thermoplastic elastomer and contains a tackifier, the top sheet and the back sheet are firmly integrated. Moreover, since the pressure at the time of integrating a surface sheet and a back surface sheet can be made lower than before by including a tackifier, it is a mat without a concavo-convex pattern due to the through holes of the porous sheet. Can be. Furthermore, as described above, the mat can be reduced in pressure during integration, the degree of compression of the back sheet is reduced, and the thickness of the back sheet is easily maintained. it can. Therefore, the mat of the present invention can be used by being placed on the carpet floor of an automobile.

(Example 1)
First, a pile made of polypropylene yarn is tufted on a spunbond nonwoven fabric base fabric made of polyester fiber, and a carpet having a styrene-butadiene rubber latex coated on the back surface of the base fabric (= surface sheet, basis weight: 1,100 g / m ² ) was prepared.

On the other hand, one side of a urethane foam sheet (weight: 40 g / m ² , density: 20 kg / m ³ , thickness 2 mm) was melted and bonded to a polyester fiber needle punched nonwoven fabric (weight: 650 g / m ² ). A two-layer back sheet was prepared.

  Further, (1) 1,2-polybutadiene (1,2-vinyl bond content = 93%, weight average molecular weight = 180,000, MI = 3.0, melting point = 105 ° C., product number = RB830 (manufactured by JSR Corporation) )), (2) Styrene-butadiene block polymer (bonded styrene = 32%, product number = TR1600 (manufactured by JSR Corporation)), (3) foaming agent (Serbon SC-855, manufactured by Eiwa Chemical Industry Co., Ltd.), And (4) C5 resin tackifier (registered trademark = Marcarez R-100AS, manufactured by Maruzen Petrochemical Co., Ltd.).

Next, the 1,2-polybutadiene, styrene-butadiene block polymer, foaming agent, and tackifier were mixed at a mass ratio of 60: 40: 4: 4, melted, extruded from a T die, and a porous sheet ( Air permeability: 153 cm ³ / cm ² / sec., Basis weight: 300 g / m ² ), and the molten porous sheet is sandwiched between the top sheet and the back sheet, and the linear pressure is 98 N / cm Through the set pair of rolls, the top sheet and the back sheet were integrated by fusing the porous sheet. The porous sheet was sandwiched so as to come into contact with the styrene / butadiene rubber latex coated surface of the top sheet and the needle punched nonwoven fabric surface of the back sheet. Then, it cut | judged to the mat shape and manufactured the mat of this invention.

(Examples 2 and 3)
A mat of the present invention was manufactured in the same manner as in Example 1 except that the linear pressure between the pair of rolls was 167 N / cm (Example 2) and 245 N / cm (Example 3).

(Examples 4 to 6)
Use of C5 resin tackifier (registered trademark = Marcaretz S-100A, manufactured by Maruzen Petrochemical Co., Ltd.) as a tackifier, 1,2-polybutadiene, styrene-butadiene block polymer, foaming agent, and tackifier The imparting agent was mixed at a mass ratio of 60: 40: 4: 10, and the air permeability of the porous sheet was 113 cm ³ / cm ² / sec. And the line pressure between the pair of rolls was 98 N / cm (Example 4), 167 N / cm (Example 5), and 245 N / cm (Example 6). Similarly, the mat of the present invention was manufactured.

(Example 7)
Use of C5 resin tackifier (registered trademark = Marcaretz S-100A, manufactured by Maruzen Petrochemical Co., Ltd.) as a tackifier, 1,2-polybutadiene, styrene-butadiene block polymer, foaming agent, and tackifier The imparting agent was mixed at a mass ratio of 60: 40: 4: 20, and the air permeability of the porous sheet was 102 cm ³ / cm ² / sec. The mat of the present invention was prepared in the same manner as in Example 1 except that the basis weight of the porous sheet was 600 g / m ² and the linear pressure between the pair of rolls was 29 N / cm. Manufactured.

(Example 8)
As the tackifier, a terpene polymer resin tackifier (YS Resin PX1000, manufactured by Yasuhara Chemical Co., Ltd.), 1,2-polybutadiene, styrene-butadiene block polymer, foaming agent, and tackifier were used. : 40: 4: 1 mixing, and the air permeability of the porous sheet was 102 cm ³ / cm ² / sec. The mat of the present invention was prepared in the same manner as in Example 1 except that the basis weight of the porous sheet was 600 g / m ² and the linear pressure between the pair of rolls was 29 N / cm. Manufactured.

Example 9
As the tackifier, a terpene polymer resin tackifier (YS Resin PX1000, manufactured by Yasuhara Chemical Co., Ltd.) was used, and the air permeability of the porous sheet was 102 cm ³ / cm ² / sec. A mat of the present invention was produced in the same manner as in Example 1 except that.

(Examples 10 and 11)
As the tackifier, a terpene phenol copolymer resin tackifier (YS Polystar T, manufactured by Yasuhara Chemical Co., Ltd.) was used, and the air permeability of the porous sheet was 102 cm ³ / cm ² / sec. The mat of the present invention was manufactured in the same manner as in Example 1, except that the linear pressure between the pair of rolls was 167 N / cm (Example 10) and 245 N / cm (Example 11). did.

(Comparative Example 1)
A mat was produced in the same manner as in Example 1 except that the linear pressure between the pair of rolls was 29 N / cm and that no tackifier was added.

(Comparative Example 2)
A mat was produced in the same manner as in Example 1 except that the pressure between the pair of rolls was 294 N / cm and that no tackifier was added.

(Evaluation of mat)
(1) Measurement of peel strength;
Each mat was cut into a width of 25 mm and a length of 150 mm to prepare a rectangular sample. Next, the carpet and the porous sheet were peeled about 25 mm from one end in the long side direction, and then the peeled portion was fixed to a chuck of a tensile tester, and the tensile speed was 200 mm / min. The maximum value during peeling at 100 mm was measured, and the arithmetic average value was taken as the peel strength. The results were as shown in Tables 1-3.
(2) Evaluation of uneven pattern;
The back sheet side surface of each mat was visually observed to evaluate whether or not the uneven pattern was observed. The results were as shown in Tables 1-3. The evaluation criteria are as follows.
A: The uneven pattern is not observed at all O: The uneven pattern is slightly observed Δ: The uneven pattern is easily observed x: The uneven pattern is remarkably observed (3) Evaluation of sound absorption;
It measured by the normal incidence method based on JIS A1405, and calculated | required the average sound absorption rate of 500-6300Hz. The results were as shown in Tables 1-3.

  From these Tables 1 to 3, when the linear pressure is weakened (Comparative Example 1), the peel strength becomes extremely weak, and conversely, when the linear pressure is strengthened (Comparative Example 2), an uneven pattern is observed and the design is poor. It became. On the other hand, the mat according to the present invention was such that the uneven pattern was not conspicuous and sufficient peel strength was obtained by adding a tackifier. Moreover, since the linear pressure at the time of integration can be made low and it can bond together, it turned out that an average sound absorption rate also improves from the comparison with the comparative example 2. FIG.

Claims (4)

A top sheet, a porous sheet having through-holes, and a back sheet are laminated in order, and is an automotive floor mat integrated by fusion of the porous sheet, and the porous sheet is mainly composed of a thermoplastic elastomer. An automobile floor mat comprising a tackifier. The automotive floor mat according to claim 1, wherein the tackifier occupies 0.95 to 20 mass% of the porous sheet. A method for producing a floor mat for an automobile in which a top sheet, a porous sheet having through-holes, and a back sheet are laminated in order and then pressed and integrated while the porous sheet is melted. What is claimed is: 1. A method for producing a floor mat for an automobile comprising using a plastic elastomer as a main component and containing a tackifier and pressurizing at a pressure of 29 N / cm to 245 N / cm. The method for producing an automobile floor mat according to claim 3, wherein the tackifier occupies 0.95 to 20 mass% of the porous sheet.