JP2541626B2 - Manufacturing method for car floor carpets - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a floor carpet laid in the interior of an automobile.

[Prior Art] Conventionally, a polyurethane foam-backed carpet is manufactured by the following method. One of them is
First, (1) a tufted carpet or a needle punched carpet having a backing lined with a thermoplastic resin such as low density polyethylene, high density polyethylene, polypropylene, and ethylene vinyl acetate copolymer on the back surface is prepared (2) The back surface is heated by an infrared heater or the like to soften and melt the backing material, and (3) this is placed on the lower mold of the carpet molding machine and pressed between it and the upper mold to form a floor-shaped carpet. (4) This molded carpet is set in the lower mold of a polyurethane injection foaming mold, (5) a predetermined gap is maintained between the mold and the upper mold, and both molds are clamped to form (6) the upper mold. The polyurethane foam raw material is injected through the opening, and the raw material is foamed and integrally molded.

As another method, (1) a polyurethane foam molded body is produced, (2) the polyurethane foam molded body is set at a desired position of a lower die of a carpet molding machine, and (3) a backing material made of a thermoplastic resin is provided. Put a lined carpet,
(4) The laminate is pressed between the upper mold of the carpet molding machine and the softened and melted backing material acts as an adhesive to be integrated with the polyurethane foam molding.

[Problems to be Solved by the Invention] Among the methods described in the prior art, in the former case, since the carpet is molded in the molding step prior to the polyurethane injection foam molding step, a dedicated molding die is used. A temporary storage space is required until the molded product is moved to the next process. Furthermore, in addition to the above-mentioned molding mold exclusively for carpets, a mold for the polyurethane injection process is required, and since multiple molds must be prepared, a large amount of cost and labor is required for mold maintenance and management, and inevitably. Continuous production was not possible. In addition, when performing this method, the polyurethane used has a stronger adhesion to the mold surface than general polymeric materials, so in order to facilitate the release of the molded product, the polyurethane foam raw material is A mold release agent, such as paraffin wax or polyethylene wax dissolved or dispersed in a hydrocarbon or alcohol solvent, must be applied each time before injection into the mold. Process is required,
There was a tendency to go against the reduction of equipment costs and shortening of the manufacturing process.

In the case of the latter by the conventional method, since separate solid layer bodies of polyurethane foam and carpet surface layer material are fixed by using a thermoplastic resin backing material as an adhesive, when used for a long time, the two There is a risk of peeling. Further, when the molded floor carpet is assembled to the floor panel and used, there is a problem that the floor panel and the foamed foam layer rub against each other to generate abnormal noise.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for manufacturing a floor carpet for an automobile, which overcomes the above-mentioned problems, can easily remove the product from the mold, shortens the process, and minimizes the equipment cost. .

[Means for Solving the Problems] In order to achieve the above object, according to the present invention, (a) a synthetic resin film (4) is laid on a floor carpet molding lower mold (7), and (b) a predetermined amount of foamed polyurethane. The raw material (9) is injected onto the upper surface of the synthetic resin film (4), and (c) between the floor carpet molding lower mold (7) and the floor carpet molding upper mold (8) which have received the foamed polyurethane raw material. Then, on the back side, backing material (2,2
The carpet (1) lined with a) is pressed while the thermoplastic resin backing material (2, 2a) is heated, and (d) at the same time, the foamed polyurethane raw material is placed on the carpet in the upper and lower molds. A floor carpet is manufactured by a step of foaming in a predetermined mold cavity formed by, and integrally molding the synthetic resin film and the carpet through a polyurethane foam.

In the step (c) of the above manufacturing method, a secondary base cloth is further provided between the carpet lined with the thermoplastic resin backing material and the floor carpet molding lower die that has received the foamed polyurethane raw material. Good to stack.

[Operation] With the above-mentioned configuration, the foamed polyurethane raw material injected into the carpet molding lower mold through the synthetic resin film spreads into various shapes such as beads on the entire lower mold. A carpet lined with a thermoplastic resin backing material is placed on this in a softened and melted state by heating the backing material, pressing it with the upper mold of the molding machine, and in a predetermined cavity between the upper and lower molds. The polyurethane raw material is foamed to form a polyurethane foam on the back surface of the carpet, and a single mold is used to manufacture an integrally molded floor carpet.

Further, in the foaming step, a nonwoven fabric is laminated on the back surface of the carpet backing material to prevent polyurethane foam from bleeding up to the carpet surface layer.

In the floor carpet of the present invention, (1) the foam synthetic resin material constituting the base material is an in-situ foaming material that generates gas in the polycondensation process of plastic to foam, and it is particularly preferable to use polyurethane foam. (2) Polyethylene, polypropylene, polystyrene, polyurethane, vinyl chloride resin and the like are used for the synthetic resin film forming the lowermost layer, and the thickness thereof is generally suitable to be 5 to 50 μm. (3) Carpets include tufted carpets and needle punched carpets, and (4) backing materials made of plastic resins such as low-density polyethylene, high-density polyethylene, polypropylene, and ethylene-vinyl acetate copolymer. It is preferable to mix calcium carbonate, barium carbonate, talc, etc. as a filler in the resin. (5) A polyester spunbond nonwoven fabric or the like is suitable as the secondary base fabric to be laminated on the back surface of the backing material.

EXAMPLES Examples will be described with reference to the drawings. FIG. 1 is a perspective view of an example of a floor carpet of the present invention, and FIG. 2 is a sectional view taken along the arrow AA of FIG. 3 and 4 are enlarged views of the circled portions B and C of FIG. 2, respectively. In FIG. 3, polyurethane foam 3
The carpet 1 lined with a backing material 2 made of a thermoplastic resin is laminated on one surface of the base material of 1, and a synthetic resin film 4 is laminated on the other surface of the base material, and the assembly of the carpet and the backing material (1 , 2) and the synthetic resin film 4 are integrally formed with the polyurethane foam 3 via the foamed polyurethane melt surface, respectively. In the portion shown in FIG. 3, the backing carpet (1, 2) and the synthetic resin film 4 have a structure in which they are directly laminated. This constitutes the floor carpet 5.

FIG. 5 is a cross-sectional view of another embodiment of the floor carpet of the present invention, which is a carpet 1a lined with a backing material 2a.
And a polyurethane foam 3a, a secondary base cloth 6 for preventing the raw material of polyurethane foam from being exuded to the surface of the carpet 1 at the time of injecting and foaming the raw material of polyurethane foam when manufacturing this structure. Laminated and further polyurethane foam
A synthetic resin film 4 is laminated on the other surface of 3a. A polyester spunbonded non-woven fabric or the like can be used as the secondary base fabric.

Next, a method for manufacturing a floor carpet according to the present invention will be described.

First, regarding the products manufactured in FIGS. 3 and 4,
(A) As shown in FIG. 6, the synthetic resin film 4 is laid on the entire surface on one side of the lower mold 7 of the molding machine. Next, (b) 7th
According to the figure, from the polyurethane foam material injection port 11 to the lower mold 7
The foamed polyurethane raw material 9 is injected toward the above synthetic resin film 4. This injection amount can be determined by appropriately adjusting the foamed polyurethane raw material injection port 11 as desired.
(C) The injected polyurethane raw material 9 is naturally foamed so that the foamed polyurethane raw material 9 spreads over the entire surface of the lower mold 7 in a semi-cured fluid state 10 and various shaped portions and beads formed on the surface. It flows into every corner.
(D) In this state, as shown in FIG. 8, the carpet 1 on which the backing material 2 made of a thermoplastic resin on the back side is heated and softened and melted in advance by an infrared heater or the like is placed on the lower mold 7 and the molding machine. It is placed between the molds 8 and is pressed between the lower mold 7 and the upper mold 8 while allowing the semi-cured polyurethane foam 10 to foam. The size of the cavity in the portion between the upper mold 8 and the lower mold 7 is determined so as to match the desired size of the polyurethane foam 3 after foaming. FIG. 9 shows a state in which the above process is completed and the upper mold 8 is removed, and the backing material 2, the polyurethane foam 3, and the synthetic resin film 4 are molded and integrated in order from the carpet 1 on the upper surface, and The carpet 5 is completed.

Furthermore, a method of manufacturing another embodiment 5a of the floor carpet of the present invention shown in FIG.
Referring to the completed state diagram of FIG. 10, in this case, as described in the step of FIG. 8 above, the one interposed between the lower mold 7 and the upper mold 8 is that the polyurethane raw material being foamed is the carpet. The secondary base cloth 6 such as a non-woven fabric for preventing the exudation on the surface of 1a is a backing material for the carpet 1a.
What is laminated on the back surface of 2a is used. Thus, as shown in FIG. 11, a floor carpet 5a in which the floor carpet 1a, the backing material 2a, the secondary base cloth 6, the polyurethane foam 3a and the synthetic resin film 4 are sequentially laminated and integrated is completed. It

[Effects of the Invention] Since the present invention is configured as described above, it has the effects described below.

According to the method for manufacturing an automobile floor carpet of claim 1, (1) carpet molding is performed using a mold in which polyurethane is injected, so that it is necessary to prepare both a carpet molding mold and a foamed polyurethane injection mold as in the conventional method. In addition, the cost can be reduced, the cost and labor required for the maintenance and management of the mold can be reduced, and the storage space for the carpet molded product can be eliminated.

(2) The floor carpet can be manufactured continuously and consistently.

(3) Since a synthetic resin film is laid between the mold and the foamed polyurethane raw material, it has excellent releasability, and the step of applying the release agent can be omitted and the step can be shortened.

(4) Since the carpet and the polyurethane foam are foamed and melt-bonded at the interface, they are tightly integrated, and there is little risk of peeling between them even after long-term use.

(5) Since the synthetic resin film is laminated on the back surface of the foamed polyurethane layer, it is hygienic, and the conventional frictional friction between the floor panel and the polyurethane foam does not occur.

In the method of claim 2, since the nonwoven fabric is interposed between the carpet backing material and the polyurethane foam raw material in the foaming step of the polyurethane foam raw material, the polyurethane foam raw material does not exude to the carpet surface during polyurethane injection foaming. , Does not spoil the appearance of the product.

[Brief description of drawings]

FIG. 1 is a perspective view of an example of a floor carpet made by the method of the present invention, FIG. 2 is a cross-sectional view taken along the arrow AA of FIG. 1, and FIGS. 2 is a partially enlarged view of the circled portions B and C of FIG. 2, FIG. 5 is a cross-sectional view of a floor carpet made by a method of another embodiment of the present invention, and FIGS. The method for manufacturing the floor carpet shown in FIG. 10, and FIGS. 10 and 11 show the steps involved in manufacturing the floor carpet shown in FIG. 1,1a …… Carpet, 2,2a …… Backing material, 3,3a …… Polyurethane foam, 4 …… Synthetic resin film, 5,5a …… Floor carpet, 6 …… Secondary base cloth, 7 …… Molding lower mold, 8 …… Molding upper mold, 9 …… Polyurethane foam raw material, 10 …… Semi-cured polyurethane foam, 11 …… Polyurethane foam raw material inlet.

Claims (2)

(57) [Claims] 1. A synthetic resin film (4) is laid on a floor carpet molding lower mold (7), and (b) a predetermined amount of foamed polyurethane raw material (9) is placed on the upper surface of the synthetic resin film (4). (C) Between the floor carpet molding lower mold (7) and the floor carpet molding upper mold (8) that have received the foamed polyurethane raw material, a backing material (2,
The carpet (1) lined with 2a) is pressed while the thermoplastic resin backing material (2, 2a) is heated, and (d) at the same time, the foamed polyurethane raw material (9) is applied to the carpet molding upper mold. (8) and the lower mold (7) are foamed in a predetermined mold cavity to integrally mold the synthetic resin film (4) and the carpet (1) through the polyurethane foam (3, 3a). A method for manufacturing an automobile floor carpet (5, 5a), comprising the steps of: 2. In the step (c), a carpet (1a) lined with a backing material (2a) made of a thermoplastic resin and a floor carpet molding lower die (7) receiving a foamed polyurethane raw material (9) are used. A secondary base fabric (6) is laminated between them.
A method for producing the floor carpet (5a) for an automobile according to the description.