JP2941190B2 - Car mat and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a car mat in the form of a tufted carpet to be laid on an automobile floor and a method for producing the same.

[0002]

2. Description of the Related Art As a car mat, there is a tufted carpet type in which a backing layer of a synthetic resin or rubber is provided on the back surface of a base fabric in which a pile yarn is tufted.
The color tone of the surface of this kind of car mat is set variously by dyeing after tufting (post-dyeing process) and coloring of the pile yarn itself to be used. Although it is possible to attach them, there has been a disadvantage that the design is still poor.

The present invention has been made in view of the above circumstances, and has as its object to provide a car mat in the form of a tufted carpet, which has a unique design that has never existed in the past and has excellent heel pad mounting workability. I have.

[0004]

In order to achieve the above object, a car mat according to the first aspect of the present invention is provided with a backing layer 3 made of synthetic resin or rubber on a base cloth 1 on which a pile yarn 2 is tufted, at least a portion of the pile yarns 2, absolute to the metal thin film discontinuously deposited on the synthetic resin film
This adopts a configuration in which the edge gold-silver yarn 4 is twisted.

[0005]

According to a second aspect of the present invention, in the car mat of the first aspect, the metal thin film of the gold-silver thread 4 is made of Sn or a Sn alloy.

[0007] The invention according to claim 3, after the claim 1 an insulating metallic yarn 4 pile yarn 2 elaborate twist was tufted to the base fabric 1 according were subjected to backing with synthetic resin or rubber on the back surface, The present invention relates to a method for manufacturing a car mat, characterized in that a heel pad 5 and / or a name plate 6 made of a synthetic resin or rubber are welded to a front surface side by high-frequency heating.

[0008]

FIG. 1 shows the basic structure of a car mat according to the present invention. In the figure, 1 is a base cloth, 2 is a pile yarn tufted to the base cloth 1, 3 is a backing layer provided on the back side of the base cloth 1, and gold and silver threads 4 are twisted into the pile yarn 2. It is rare. However, in such a car mat, since the metallic luster of the gold and silver yarns 4 is added to the color tone of the pile yarns 2, the mat surface shows a unique glittering luster, and thus has an unprecedented superior design. Demonstrate.

The gold-silver thread 4 is formed by attaching a metal thin film to a synthetic resin film. This is a polyester such as polyethylene terephthalate, rigid polyvinyl chloride,
Polyolefins such as polypropylene and polyethylene,
Vacuum evaporation, ion plating, sputtering, CVD on synthetic resin film such as polyamide (nylon)
A metal thin film having a thickness of several tens to 1000 mm is applied by a thin film forming technique such as a chemical vapor deposition method, and this film is attached as it is or after two sheets are laminated, and then formed into a fine thread by a micro slitter. Cutting (generally 30.3mm
= 1 to 80 equal to 100) flat gold silver yarn, or this flat gold silver yarn is made of rayon yarn, nylon yarn, polyester yarn, etc. as a core yarn at a rate of about 20 to 2000 times / m in a round twist, a haori twist, Twisted gold-silver yarn twisted by an appropriate method such as bellows twisting or tusk twisting. Incidentally, such gold and silver yarns are generally prepared by vacuum deposition (a degree of vacuum of 10 ^-4 To
(approximately rr) to form a metal thin film, but the mainstream is a metal thin film with an undercoat layer of an appropriate resin interposed under the metal thin film, or a transparent protective layer formed by coating or sticking a film on the metal thin film with an appropriate resin. Alternatively, those provided with a colored protective layer in which various colors such as gold are exposed by a dye or the like are of course included in the gold-silver thread of the present invention.

However, as the metal thin film of the gold-silver thread 4, Al, Ag, Sn, Cu, Cr, Pb, Zn, B
Examples thereof include i, Ti, Fe, Co, Ni, and alloys thereof, and in particular, in the present invention, those made of Sn or a Sn alloy are recommended. That is, in the case of car mats, after the pile yarn 2 is tufted on the base cloth 1, the required coloring is often applied by post-dyeing. However, those having an Al thin film, which is most commonly used as gold and silver yarn, are subjected to high pressure dyeing or reactive dyeing. Is difficult to withstand the dyeing process. On the other hand, a gold-silver yarn having a thin film of Sn or a Sn alloy has advantages in that it has excellent resistance to the above-described dyeing process and is inexpensive. In addition, as a Sn alloy, a Sn-Al alloy and a Sn-Si alloy are suitable.

On the other hand, a heel pad made of a thermoplastic resin such as polyvinyl chloride, rubber, or the like is sometimes attached to a car mat at a position where the heel of an occupant hits. In particular, a car mat for a driver's seat with a heel pad is often used. Have been. Further, in order to display a brand name or a manufacturer name, a nameplate made of the same thermoplastic resin or rubber is often attached alone or together with the heel pad. Then
In the car mat of the tufted carpet type according to the present invention, as shown in FIG. 2, the heel pad 5 and the nameplate 6 are fixed to the pile thread 2 planting surface. As a fixing means, a welding method using a high-frequency welder is used from the viewpoint of processing efficiency, that is, a car mat on which a thick sheet for a heel pad is placed at a predetermined position on a pile yarn planting surface is arranged on a base plate of the welder, By applying a high-frequency electric field in a state where the thick sheet is pressurized from above through a mold provided on a plate, the thick sheet is softened and melted by dielectric heating, and thereby the pile yarn setting surface of the heel pad It is preferable to perform the welding to the surface and the molding of the surface (patterning of the unevenness) at the same time.

However, when the ordinary gold-silver yarn 4 is twisted into the pile yarn 2, the heel pad 5 and the nameplate 6 are welded by the above-described high-frequency welder because the gold-silver yarn 4 shows conductivity by a metal thin film. In such a case, there is a problem in that the electric charge of the gold and silver yarn charged at a high frequency causes discharge, and the spark damages the car mat. Therefore, in a car mat in which the heel pad 5 and the nameplate 6 are welded by high-frequency heating, it is preferable to use an insulating gold-silver thread having a discontinuous metal thin film as the gold-silver thread 4. This insulating gold-silver yarn is obtained by cutting a metal vapor-deposited film as disclosed in, for example, Japanese Patent Publication No. 6-6783, and the metal thin film has a sea-island-like structure separated from each other on the synthetic resin film. However, it does not exhibit conductivity despite having metallic luster, and does not generate sparks even when a high-frequency electric field is applied.

In the above-mentioned insulating gold-silver yarn, the size of the island of the metal thin film having the sea-island structure is 200Å-1 μm.
It is preferable that the distance between the islands is about 100 to 5000 °, and if the size of the islands is too large or the distance between the islands is too small, a discharge may occur during high-frequency heating,
Conversely, if the size of the islands is too small or the distance between the islands is too large, the metallic luster will be poor. Also, among such insulating gold-silver yarns, it is particularly recommended that the metal thin film is made of Sn or a Sn alloy.

As the pile yarn 2 into which the gold and silver yarn 4 is twisted,
Polyamide (nylon), polyester, polypropylene, polyacryl, wool, and other commonly used pile yarns for car mats can be used without any problems, and the thickness is 300.
It is preferably about 5000 denier, and the coloring may be any of original (excluding wool), first dyed and post dyed. The gold and silver yarn 4 is preferably entangled with a suitable twist of the pile yarn 2 beforehand, for example, 20 to 26.
It may be twisted at a rate of about 0 times / m. The vial yarn 2 into which the gold and silver yarn 4 is twisted may be heat set.

As the base fabric 1, polyester nonwoven fabric, polyolefin nonwoven fabric, polyester tape yarn woven fabric,
Polyolefin tape yarn woven fabric and the like are preferred. And the tuft condition is 5/32, 1/8, 1/10, 5/6
All gauges generally used for tufted carpets, such as 4 gauges, are applicable.

The backing layer 3 is for imparting the dimensions and shape stability of the car mat, the pile yarn fixing property, the anti-slip function, and the like. The backing layer 3 is made of rubber or synthetic resin, and has a tufted pile fabric 2. 1 (tufted cloth) is laminated and integrated by thermocompression bonding or bonding, melt coating, or the like of the sheet material. Then, in this backing layer 3,
Various additives such as a coloring agent and a filler may be contained.

Although FIG. 1 shows an example in which the pile yarn is a cut pile, a loop pile may be used.
Further, in the car mat of the present invention, it is not necessary that all pile yarns to be tufted into the base fabric are twisted gold and silver yarns, and a pile yarn containing gold and silver yarns and a pile yarn not containing gold and silver yarns are used. A combination form may be used, and the combination ratio can be freely set. In addition, the overall shape of the car mat,
The shape of the heel pad and the nameplate, the planting density and length of the pile yarn, etc. can be freely set.

The procedure for manufacturing the car mat is not particularly limited, but generally, tufting of the pile yarn with respect to the base fabric → dyeing (performed if necessary) → sealing treatment → size of the mat unit Rough cutting → backing → punching out to the final car mat shape → high-frequency welding processing to provide a heel pad and nameplate → overlock processing to protect the periphery of the mat. The above-mentioned filling process is to prevent the pile yarn from easily coming off the base fabric by applying rubber or the like to the back surface of the tufted fabric.

[0019]

EXAMPLE Using a tufting machine, 1225 was placed on a 0.56 mm thick base cloth made of polyethylene terephthalate nonwoven fabric.
Three denier nylon yarns were twisted 180 times / mS each, and then the three yarns were integrally twisted 130 times / mZ, and two 1225 denier nylon yarns were twisted to form an insulating gold-silver yarn. And the set yarn twisted 50 times / mZ, and the former / the latter is alternately tufted in a striped ratio at a ratio of 4/1, subjected to post-dyeing processing, and further coated with styrene-butadiene rubber on the back side of the fabric. The cut pile fabric for car mats in which the twist ratio of the gold and silver yarns in the pile yarns was 2.4% was produced. This fabric is 5/3
2 gauge cut pile, 8.2 stitches, pile height 1
7 mm. In addition, as a gold and silver thread, a thickness of 12 μm
Of polyethylene terephthalate film by semi-continuous vacuum evaporation, the size of the islands is about 1000 mm and the distance between the islands is 100 mm
Is formed, and a transparent protective layer having a thickness of 2 μm is formed by an acrylic-melamine resin on the vapor deposition surface side of the film, and the transparent protective layer is formed by a microslitter.
What was cut so that 0.3 mm (1 dimension) was equally divided into 80 was used.

Next, after a rubber sheet is thermocompression-bonded to the back side of the cut pile fabric to form a backing layer having a thickness of 2.0 mm, the backing layer is cut into a car mat shape (55 cm × 72 cm). A polyvinyl chloride sheet for a heel pad (11 cm × 18 cm) and a piece of polyvinyl chloride for a nameplate (3 cm × 10 cm) are placed in a predetermined position, and a high-frequency electric field is applied to the sheet under pressure by a high-frequency welder, so that a heel is applied. Weld and mold the pad and nameplate,
A car mat was prepared by performing an overlock process. The obtained car mat had a unique lame-like surface in which countless glittering parts were scattered throughout, and had an excellent design property never before. In addition, no spark damage occurred during the welding and molding of the heel pad.

[0021]

According to the first aspect of the present invention, as a car mat in which a backing layer is provided on a base fabric in which a pile yarn is tufted, a metal thin film is applied to a synthetic resin film on at least a part of the pile yarn. Because the gold and silver yarns are twisted, the color tone of the pile yarn is added to the metallic luster of the gold and silver yarns, and the surface shows a unique glittery appearance, thus exhibiting unprecedented superior design characteristics Is provided.

According to the first aspect of the present invention, as the car mat, since the gold-silver yarn twisted into the pile yarn is an insulating gold-silver yarn, the heel pad made of synthetic resin or rubber by high-frequency heating on the mat surface. And a nameplate can be welded without fear of being damaged by sparks, thereby achieving high production efficiency.

According to the second aspect of the present invention, since the metal thin film of the gold and silver yarn is Sn or Sn alloy as the car mat, post-dyeing by high-pressure dyeing or reactive dyeing after the tufting of the pile yarn is possible. Therefore, a color tone and a pattern with a high degree of freedom are provided.

According to the third aspect of the present invention, it is possible to manufacture a car mat having a heel pad or a nameplate made of synthetic resin or rubber on the surface on which pile yarns are planted, with high production efficiency and without causing damage.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a main part showing a basic configuration of a car mat of the present invention.

FIG. 2 is a plan view showing one embodiment of the car mat.

[Explanation of symbols]

 Reference Signs List 1 base cloth 2 pile yarn 3 backing layer 4 gold and silver yarn 5 heel pad 6 nameplate

──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Masanori Fujiwara 5-125 Higashi-Arioka, Itami-shi, Hyogo Tori Co., Ltd. No. (56) References JP-A-56-148284 (JP, U) JP-A-6-16482 (JP, U) (58) Fields investigated (Int. Cl. ⁶ , DB name) B32B 1/00-35 / 00 B60N 3/04 D02G 3/12

Claims (3)

(57) [Claims] 1. A pile yarn backing layer is provided with synthetic resin or rubber base fabric that tufting, at least a portion of said pile yarn, the metal thin film on a synthetic resin film not
A car mat comprising continuously insulated gold and silver yarns twisted. 2. The car mat according to claim 1 , wherein the metal thin film of gold and silver yarn is made of Sn or a Sn alloy. 3. A pile yarn in which the insulating gold-silver yarn according to claim 1 is twisted is tufted on a base cloth, and the back surface thereof is lined with a synthetic resin or rubber. A method for manufacturing a car mat, comprising welding a heel pad and / or a nameplate comprising high-frequency heating.