JP3252885B2 - Carpet 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 method of manufacturing a carpet mainly laid on a floor panel of an automobile.

[0002]

2. Description of the Related Art Tuft carpets, needle punch carpets and the like are laid on the floor of a vehicle. These carpets are composed of a composite, for example, a needle-punched carpet of polypropylene or the like serving as a skin layer, a mixed layer of latex and fibers located immediately below, a polyethylene molded layer in the middle, and a vibration-damping and sound-proofing layer serving as a lowermost layer. Of each of the felt layers. The needle punch carpet having this composite structure is manufactured through the following steps.

(1) A process of producing a needle-punched carpet by performing needle punching on a fiber web.

(2) A step of applying latex to the back of the needle punch carpet to retain the fibers.

(3) A step of applying polyethylene to the back of the needle punch carpet to form a polyethylene sheet.

(4) A step of manufacturing felt.

(5) A step of punching the felt according to a mold.

(6) A heated needle punch carpet is disposed on the die-cut felt layer disposed in the press die, and when the polyethylene sheet is in a molten state, the polyethylene sheet is formed into a floor panel shape by cold pressing. And forming a needle punch and crimping felt.

As described above, in a general carpet, after manufacturing a needle punched carpet to be a surface layer, polyethylene is applied to the back surface (latex layer), and at the same time as the press molding, the felt is adhered by the anchor effect. .

[0010]

However, the conventional carpet manufacturing method described above involves a large number of manufacturing steps, which increases processing costs.

Accordingly, the present invention aims at reducing the material and simplifying the processing steps by imparting the shape retaining property of the needle punch carpet itself and the cushioning and vibration damping properties of the felt. It is intended to be.

[0012]

Means for Solving the Problems In order to solve the above-mentioned problems and to achieve the object, the method for producing a carpet according to the present invention comprises the steps of: A step of laminating a shaped fiber layer with regularity after the melt fiber is mixed into the regular fiber at a high rate and after curing by heat treatment, and when the melt fiber is mixed into the regular fiber at a low rate on the shaped fiber layer; The method is characterized by comprising a step of stacking upper layers and a step of cooling and pressing after heating the respective layers. In this case, the uppermost layer becomes a fibrous skin.

As a step before heating the stacked layers, a step of performing needle punching on each of the layers to entangle the fibers may be included.

Specifically, the regular fiber is a synthetic fiber such as polyester or polypropylene, a natural fiber such as cotton or wool, or an anti-wool of each of the above fibers, and the melt fiber is a polyester fiber. Melting point fiber,
Olefin-based low-melting fiber, or when the regular fiber is a natural fiber such as polyester fiber and cotton, wool,
It is characterized by a polypropylene fiber having a lower melting point.

[0015]

[Function] Even if the buffer / damping layer having a low melt fiber rate and the molded shape retaining layer having a high rate are heated in the same manner, due to the difference in the mixing ratio of the melt fiber, the buffer / damping layer has a low melt fiber. At the confounding points, the welded portions are scattered and formed, and the cushioning / damping layer has appropriate elasticity as a whole. On the other hand, in the molded shape-retaining layer, the welded portion is formed at a high density, and as a result, the molded shape-retaining layer has a hard plate shape as a whole.

The present invention utilizes such a difference in the properties of the two layers due to the high and low mixing ratio of the melt fiber.
After the two layers are overlaid, the layers having a cushioning / damping effect and the layers having a shape-retaining effect can be easily formed by performing needle punching, heating and pressing as a whole.

[0017]

Next, referring to FIGS. 1 (a) to 1 (c),
A first embodiment of the present invention will be described.

This carpet manufacturing method is characterized by having the following steps (1) to (6).

(1) As shown in FIG. 1A, a melt fiber 1 is added to a regular fiber 2 by a weight ratio of, for example, 50%.
%, Preferably about 20%. Here, "regular fibers" include synthetic fibers such as polyester and polypropylene or cotton, natural fibers such as wool or their anti-wool,
"Melt fiber" means polyester-based low-melting fiber, olefin-based low-melting fiber, and polypropylene fiber having a lower melting point (melting temperature) when the regular fiber 2 is a natural fiber such as polyester fiber, cotton, or wool. And so on. In short, regular fiber and melt fiber are relative concepts, and fibers having a melting point lower than that of regular fiber 2 are collectively referred to as melt fiber 1.
That. The melt fiber 1 also includes a so-called core-sheath fiber in which a core portion of a regular fiber is covered with a sheath portion of the melt fiber.

(2) On the upper surface of the buffer / damping layer A, the regular fiber 2 and the melt fiber 1 are, for example, 50% by weight.
As described above, the molded shape-retaining layer B, which is preferably mixed at about 80%, is provided.

(3) Buffer / damping layer A and molded shape-retaining layer B
Is heated above the melting point of the melt fiber 1 and below the melting point of the regular fiber 2. Thereby, the heated melt fiber 1 becomes a regular fiber 2 of the buffer / damping layer A.
A welded portion M is formed at the point of confounding between the fiber and the regular fiber 2 of the molded shape-retaining layer B. The two layers A and B are integrated at the mutual boundary surface with the melt fiber 1 as a medium.

(4) As shown in FIG. 3A, the regular fiber 2 and the melt fiber 1
Is disposed, for example, in a weight ratio of 50% or less, preferably about 20%. The top layer C is made thin by adjusting the color and texture as needed.

(5) After heating the buffer / damping layer A, the molded shape-retaining layer B and the uppermost layer C at a temperature higher than the melting point of the melt fiber 1 and lower than the melting point of the regular fiber 2 as shown in FIG. Is placed between the upper and lower molds X and Y of the cooling press, and the layers A, B and C are pressed while being cooled from the uppermost layer C side.

When cooled to room temperature by the molds X and Y, the molded shape-retaining layer B hardens, so that the entire carpet is held in a stable predetermined shape as shown in FIG. 1 (c). As a result, according to the present embodiment, the step of holding the back surface of the needle punch with latex and welding the mixed layer of latex and fiber with the polyethylene sheet as in the related art becomes unnecessary. Therefore, it is possible to manufacture a carpet at extremely low cost by reducing materials and omitting the processing steps. Further, by adjusting the thickness and weight of the cushioning / damping layer A, it is possible to improve the shock-absorbing performance such as impact to the same level as a general carpet.

Further, according to this embodiment, since the molded shape-preserving layer B, which tends to give a gloss when pressed, is hidden by the uppermost layer C containing a large amount of the regular fiber 2, the appearance becomes matte. The texture is fibrous.

Next, a second embodiment of the present invention will be described with reference to FIG. The method of making this carpet is
As a step before the pressing step (5) in the first embodiment, a step of performing a needle punch (not shown) from the side of the uppermost layer C to the buffering / damping layer A as shown in FIG. . In FIG. 2, a broken line indicates a punched portion. The other steps are the same as in the first embodiment, and a description thereof will be omitted. According to the present embodiment, the shape-retaining layer B can be formed at a high density, and the shape-retaining effect can be enhanced.

The carpet manufactured by the manufacturing method of each embodiment described above has an apparent specific gravity of 0.1 g / cm ³ or less, and has an excellent buffering effect against impacts and the like.

Further, by using an optional mat made of vinyl chloride so as to be stacked on the carpet, the optional mat becomes a so-called heavy layer, and the vibration sound from the cushioning / damping layer A is further effectively prevented. To
There is hope for the soundproofing effect.

[0029]

As described above, according to the method for manufacturing a carpet according to the present invention, extremely little is formed from the molded shape retaining layer to the cushioning / damping layer, or from the uppermost layer to the molded shape retaining layer and the cushioning / damping layer. Can be integrated in the process. In addition, since the uppermost layer is provided on the upper surface of the molded shape-retaining layer, a natural fiber feeling can be brought out on the upper surface of the carpet, and the overall texture can be further improved.

In addition, by performing needle punching from the uppermost layer to the buffer / damping layer, the density of the molded / retained layer can be increased to improve the molded / retained shape effect. Since the thickness is hardly changed, the buffering / damping effect is not reduced.

Therefore, the carpet according to the present invention is particularly useful mainly as a carpet for automobiles, and cost reduction can be further promoted by saving labor of materials and processing steps.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a first embodiment of a method for manufacturing a carpet.

FIG. 2 is a longitudinal sectional view showing a second embodiment of the method for manufacturing a carpet.

[Explanation of symbols]

 A cushioning / damping layer B molded shape-retaining layer C top layer 1 melt fiber 2 regular fiber

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B60N 3/04

Claims (3)

(57) [Claims] 1. A molded and shaped article having a high ratio of melt fibers mixed with regular fibers on a buffer / vibration damping layer in which melt fibers are mixed with regular fibers at a low ratio, and having a fixed form after being cured by heat treatment. A carpet comprising a step of stacking layers, a step of stacking an uppermost layer in which melt fibers are mixed with regular fibers at a low rate on the molded shape-retaining layer, and a step of cooling and pressing after heating each of the layers. Manufacturing method. 2. A step of superposing the molded shape-retaining layer on the cushioning / damping layer, a step of superposing the uppermost layer on the molded shape-retaining layer, and applying a needle punch to each of the layers to entangle the fibers. The method for producing a carpet according to claim 1 , further comprising: a step of heating and cooling and pressing the respective layers. 3. The regular fiber is a synthetic fiber such as polyester or polypropylene, a natural fiber such as cotton or wool, or an anti-wool of each fiber, wherein the melt fiber is a polyester-based low melting fiber; The method for producing a carpet according to claim 1 or 2 , wherein, when the olefin-based low-melting fiber or the regular fiber is a natural fiber such as polyester fiber, cotton, or wool, the fiber is a polypropylene fiber or a polyethylene fiber having a lower melting point than the natural fiber.