JP3521713B2 - Automotive floor carpet and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile floor carpet and a method for manufacturing the same, and more particularly to an automobile floor carpet that is lightweight and has good sound insulation performance and a method for manufacturing the same.

[0002]

2. Description of the Related Art Automotive floor carpets are required to not only decorate the interior of a vehicle but also to block the sound and vibration input from the floor panel. Generally, a floor carpet for an automobile has a structure in which a carpet skin, a backing material, and a cushioning material layer are laminated in this order. It has been proposed to use a polyester short-fiber non-woven fabric as a cushioning material for an automobile floor carpet that is lightweight and has good sound insulation performance.

A cushioning material for an automobile floor carpet requires not only sound insulation properties but also a repulsive force assuming that it is stepped on by an occupant's foot. Therefore, a polyester nonwoven fabric having a relatively large average fineness is used. In the conventional automobile floor carpet, since the cushioning material is designed based on the portion stepped on by the occupant, the polyester nonwoven fabric having a relatively large fineness is also used for the center tunnel portion having a large opening.

However, in the vicinity of the center tunnel, a large opening is provided for the carpet due to the layout of the operation system device. For this reason, it is a main sound entry path, and there is a problem in that the effect of preventing sound entry is poor if a cushioning material having a high degree of fineness and poor sound absorption performance is used in this part.

[0005]

The floor carpet for an automobile of the present invention is provided at a portion where a load of an occupant is applied, that is, at an upper surface or a side surface of a center tunnel which has many openings due to a relation between a floor surface on which the floor carpet is mounted and an operation system device. In addition, the hardness and sound absorption coefficient of the cushioning material can be changed for each part by using at least two types of polyester non-woven fabrics having different blending and / or density, and each cushioning material can be hot press molded at the same time so that there is no gap between them. It is an object of the present invention to solve the above problems by being characterized in that they are formed by overlapping.

[0006]

In order to achieve the above object, an automobile floor carpet of the present invention is present between a floor carpet mounting floor surface and a floor panel composed of a top surface and side surfaces of a center tunnel and a floor carpet skin. The cushioning material is composed of a polyester short fiber non-woven fabric hot-pressed, and has a fiber blend and / or
Alternatively, a cushioning material made of at least two types of polyester non-woven fabrics having different basis weights (area densities) is provided, and the respective cushioning materials are formed so as to overlap each other without a gap.

The present invention also provides a method for manufacturing an automobile floor carpet comprising the following steps, which comprises a web of polyester fibers A constituting a cushioning material to be provided on a floor carpet mounting floor surface, and a center. After the webs of polyester fiber B constituting the cushioning material to be provided on the upper surface and the side surfaces of the tunnel are laminated using a card cloth layer or an air lay, respectively, the temperature is 180 to 2.
Heat treatment at 10 ℃ to form a block-shaped non-woven fabric,
The block-shaped non-woven fabric corresponding to the floor carpet-attached floor surface is arranged at a distance from each other, and the block-shaped non-woven fabric corresponding to the top and side surfaces of the center tunnel corresponds to the floor carpet-attached floor surface. Set in the interval of the block-shaped non-woven fabric roll, and heat the set block-shaped non-woven fabric roll to a temperature of up to 200 ° C.
Then, the molded cushioning material is obtained by press molding, and the cushioning material thus obtained and the floor carpet skin material are adhered to each other to obtain an automobile floor carpet.

Yet another method of the present invention provides a method for manufacturing an automobile floor carpet comprising the steps of: a polyester fiber A which constitutes a cushioning material to be provided on a floor carpet mounting floor surface. Laminate the webs using a card cross layer or air-laid, and
Heat treatment is performed at 80 to 210 ° C. to form a block-shaped non-woven fabric raw material, and the obtained non-woven fabric raw fabric is fed to a conveyor at intervals, while a web of another polyester fiber having a different composition and / or a different date is used. The block-shaped non-woven fabric raw material is obtained by arranging the block-shaped non-woven fabric raw material in an integrated manner by heat-treating at a temperature of 180 to 210 ° C.
It is characterized in that it is heated to a temperature of up to 00 ° C. and then press-molded to obtain a cushioning material, and then the obtained cushioning material and the floor carpet skin material are adhered to obtain an automobile floor carpet.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION As described above, in the automobile floor carpet of the present invention, a non-woven fabric composed of at least two kinds of polyester non-woven fabric is used, and the cushioning material 1 is not applied to the portion to which the load is applied, that is, the floor carpet mounting floor surface. The cushioning material 2 is formed on the upper surface and the side surface of the center tunnel in parallel with the side members as shown in FIG. 1 so that the non-woven fabrics overlap each other without a gap (circle in FIG. 1 (C)). The overlapping is formed here in order to obtain smoothness of the carpet surface. The molded cushioning material (FIG. 1 (C)) is bonded to the carpet skin material 4 having the backing material 3 on the back part to form an automobile floor carpet (FIGS. 1 (A) and 1 (B)). Furthermore, FIG.
In Fig. 6, the cushioning material has a relief shape at the portion where the seat member 14 of the cross member 12 is attached, and the cushioning material is compressed (see Fig. 6). In addition, in FIG. 6, P is a portion where the cushioning material has an escape shape (compression).

As a method of changing the hardness or sound absorption coefficient of the cushioning material, a method of changing the density of the polyester short fiber non-woven fabric forming each cushioning material can be considered, but a method of changing the hardness or sound absorption coefficient by changing the average fineness. Is particularly preferable. The greater the fineness, the higher the repulsive force, but the sound absorbing performance decreases. In the center tunnel, where the load is not applied, there are many openings in the carpet due to the existence of automobile operation devices, and this is the main sound entry path. Therefore, it is preferable to use a non-woven fabric having a large average fineness in a portion to which a load is applied to increase the repulsive force, while using a non-woven fabric having a small average fineness with good sound absorbing performance around the center tunnel where no load is applied.

The polyester short-fiber non-woven fabric which constitutes the cushioning material for the portion to which the load is applied is used in the range of 4 to 40 denier as the average fineness, more preferably 6 to 20 denier, and the average apparent density of the end portion and the stopper is 0.02 to 0.1 excluding special parts such as points and relief shapes of other parts
Used in the range of g / cm ³ , but 0.025 to 0.08 g /
cm ³ is more preferred. If the amount is out of these ranges, repulsion force, durability, sound vibration performance, weight increase, and cost increase may be caused. As a fiber composition, the matrix fiber may be solid or hollow with 5 to 20 denier. Side-by-side type conjugate fiber (for example, polyester fiber and conjugate fiber of polyester fiber) Binder fiber is composed of core-sheath type low melting point fiber of 2 to 15 denier (for example, polyester fiber having a melting point of 110 ° C. or more), and their respective mixing ratios Is used in the range of 70 to 90% by weight of matrix fiber and 10 to 30% by weight of binder fiber. In particular, the side-by-side type conjugate fiber is preferable in terms of weight reduction because it has lower density and repulsive force than regular fibers.

Center tunnel average fineness with a large opening so that a load is not applied The polyester short fiber nonwoven fabric constituting the cushioning material provided on the upper and side surfaces is used in the range of 1.5 to 3 denier, and the average apparent density is the above-mentioned special value. employed in the range of 0.02~0.1g / cm ³ except a part but, 0.025~0.08g / cm ³ is more preferable.
If it deviates from these ranges, the shape retention property, the sound vibration performance, the weight, and the cost increase. In addition, in order to improve the sound absorbing performance, a portion having a modified cross-sectional shape may be used for a portion where no load is applied. As the fiber composition of the buffer material, the matrix fiber A is 1.5 to 3
A denier fiber, a matrix fiber B of 4 to 8 denier, and a binder fiber of 1.5 to 2 denier of core-sheath type low melting point fiber (for example, polyester fiber having a melting point of 110 ° C. or higher), and their respective blending ratios are matrix fibers. The total amount of A and matrix fibers B is 70 to 90% by weight,
The matrix fiber B is contained in at least 20% by weight or more, and the binder fiber is used in the range of 10 to 30% by weight.

At least one of the 10 to 30% by weight of the binder fibers used in the portion to which the load is applied is used.
0% by weight is preferably a crystalline low melting point polyester, and if less than 10% by weight, the compression set against heat becomes large, which is not preferable.

As a method for producing at least two types of polyester nonwoven fabrics having different blending and / or basis weight (area density), in addition to the method of separately molding each block-shaped nonwoven fabric fabric, as shown in FIG. An integrated block-shaped non-woven fabric raw material composed of at least two types of blends or densities produced by using three card cross layers or air lays, and dropping the webs onto the conveyor from the respective web supply ports without gaps. It is also possible to mold and use.

Further, as shown in FIG. 3, while at least one kind of block-shaped non-woven fabric raw material is previously supplied to the conveyor, another kind of polyester fiber having a different composition and the like is further fed from the web supply port to the conveyor without leaving a gap. It is also possible to form and use an integrated block-shaped non-woven fabric raw material which is made by dropping and is made of at least two kinds of blends or densities.

In order to produce a non-woven fabric raw material integrated by both of the above methods, the web is heat-treated at 180 to 200 ° C. to bond the two types of raw fabric. According to such a method, the binder fiber contained in the web acts as a binder, and two kinds of webs are bonded to each other to obtain a non-woven fabric original fabric. Further, a treatment such as needle punching may be performed on the joint portion as necessary.

Examples of the present invention and comparative examples will be described below.

[0018]

Examples Example 1 As a fiber mixture of a cushioning material for a portion on which an occupant is loaded, that is, a floor surface on which a floor carpet is mounted, 80% of a side-by-side type hollow conjugate polyester fiber having 13 denier matrix fibers and 2 denier binder fibers are used. 20% of core-sheath type low melting point fiber (crystalline polyester fiber having a melting point of 170 ° C.) and a basis weight of 750 g / m ² .

As the fiber blend of the buffer material in the center tunnel portion, the matrix fiber A is 60% polyester fiber having 2 denier, the matrix fiber B is 6 denier hollow conjugate polyester fiber is 20%, and the binder fiber is 2 denier. Core-sheath type low melting point fiber (melting point is 1
10% polyester fiber) is 20% and the basis weight is 50
It was set to 0 g / m ² .

Each fiber was laminated by using a card cloth layer and heat-treated at an internal temperature of about 200 ° C. to obtain a block-shaped non-woven fabric. As shown in FIG. 4, a block-shaped non-woven fabric raw material 7 corresponding to a portion on which an occupant is loaded was set around both ends of a block-shaped non-woven fabric raw material 8 corresponding to a center tunnel. Both of them are heated to 200 ° C., and the upper mold 9 for cushioning material molding and the lower mold 10 for cushioning material molding are rapidly pressed to perform cushioning 1 corresponding to a portion to which a load is applied and cushioning corresponding to the center tunnel. A cushioning material in which the material 2 was integrated was obtained. After this cushioning material was set in the skin forming lower die, it was previously laminated on the surface of the floor carpet.
A sheet of polyethylene of 00 g / m ² was melted and placed in a skin forming mold to bond the skin material and the cushioning material. The standard thickness of the cushioning material after molding is 30 at the part where the occupant's load is applied.
mm, and a portion where no load is applied was set to 20 mm. In both cases, the density of the cushioning material after molding is 0.
It becomes 025 g / cm ³ .

COMPARATIVE EXAMPLE A side-by-side type hollow conjugate polyester fiber 8 having 13 denier matrix fibers over the entire cushioning material 8
The content was 0%, the binder fiber was 2% and the core-sheath type low melting point fiber (crystalline polyester fiber having a melting point of 170 ° C.) was 20%, and the basis weight was 750 g / m ² . Molding of the carpet was performed in the same manner as in Example 1 so that the reference thickness of the portion to which the load was applied was 30 mm and the thickness of the portion to which the load was not applied was 20 mm. As a result, portions consuming load 0.025 g / cm ^3, the density of the portion not written the load became 0.0375 g / cm ^3.

FIG. 5 shows the results of an acoustic vibration test conducted by mounting the carpets obtained in Example 1 and the comparative example on a vehicle. FIG. 5 shows Example 1 in which the comparison example is set to 0 dB as a reference.
It shows the sound insulation performance of. It was found that the example improved the overall performance by about 2 dB, especially 2 to 4 dB at a high frequency of 1000 Hz or more, and the sound insulation performance was improved. In addition, Example 1 in which the unit weight of the thin tunnel portion is reduced has the advantage of being lighter than the comparative example. This result is considered to be the result of increasing the sound absorption coefficient by reducing the average fineness of the center tunnel portion having many openings.

Example 2 Example 2 shows an example in which three card layers were used to form a fiber body in which two different types of polyester fiber bodies were previously integrated in a block shape.

In the card layers at both ends corresponding to the portion on which the load of the occupant is applied, side-by-side type hollow conjugate polyester fiber of 13 denier matrix fiber 80% and binder fiber of 2 denier core-sheath type low melting point fiber ( Crystalline polyester fiber with a melting point of 170 ° C)
20% was set.

In the central card layer corresponding to the center tunnel portion, 60% of the matrix fiber A is 2% denier polyester fiber and 6% of matrix fiber B.
20 Denier Hollow Conjugate Polyester Fibers
%, And a core-sheath type low melting point fiber having a binder fiber of 2 denier (polyester fiber having a melting point of 110 ° C.) was set to 20%.

As shown in FIG. 2, the webs supplied from the web supply ports 5 of the three card cloth layers are dropped onto the conveyor 6 without any clearance and heat-treated at 200 ° C., and the original fabric weight of both ends is 750 g / m 2. ² , the central fabric weight is 500g
An integrated block-shaped non-woven fabric original fabric X composed of two types of polyester fiber blends of / m ² was obtained.

Example 1 is an integrated block-shaped material.
In the same manner as above, heating was performed until the temperature reached 200 ° C., and prompt press molding was performed. Hereinafter, the floor carpet skin material and the cushioning material were adhered by the same operation as in Example 1. The density of the cushioning material after molding was 30 mm in the part to which the load of the occupant was applied and 20 mm in the part to which the load was not applied, and the density was 0.025 g / cm ³ except for the special part.

Carrying on the carpet obtained in Example 2,
As a result of conducting the acoustic vibration test, it was found that the results of Example 2 were almost the same as those of Example 1 and that the sound insulation performance was improved.

Example 3 In Example 3, as shown in FIG. 3, while supplying a block-shaped raw material of one kind of polyester fiber body previously heat-treated to a conveyor, another kind of polyester fiber having a different composition etc. After the web was dropped from the web supply port 5 onto the conveyor 6 without any gaps, the web was heat-treated again to produce an integrated block-shaped nonwoven fabric fabric.

That is, a block having 80% of side-by-side type hollow conjugate polyester fiber having 13 denier matrix fiber and 20% of core-sheath type low melting point fiber (crystalline polyester fiber having a melting point of 170 ° C.) having 2 denier binder fiber. -Shaped non-woven fabric (weight: 750 g
/ M ² ) Y was set at both ends on a portion to which a load is applied, that is, a conveyor corresponding to the floor surface on which the floor carpet is mounted.

As a composition corresponding to the center tunnel,
Matrix fiber A is 2% denier polyester fiber 60%, matrix fiber B is 6 denier hollow conjugate polyester fiber 20%, binder fiber 2
Density core-sheath type low melting point fiber (polyester fiber having a melting point of 110 ° C.) is 20%, and a block-shaped non-woven fabric raw material is supplied from the web feeding port 5 of the card cloth layer to the center of the conveyor set at both ends. 500 g / m ²
The web was dropped so as not to generate a gap and heat-treated to obtain an integrated block-shaped non-woven fabric original fabric Z composed of two kinds of polyester fiber blends.

The integrated block-shaped nonwoven fabric raw material was heated to 200 ° C. in the same manner as in Example 1 and promptly press-molded. Hereinafter, the floor carpet skin material and the cushioning material were adhered by the same operation as in Example 1. The density of the cushioning material after molding is 0.025 g / cm, except for the special parts in the part where the occupant is weighted and the center tunnel.
It was set to be ^3.

The carpet obtained in Example 3 was mounted on a vehicle,
As a result of conducting the acoustic vibration test, it was found that the results of Example 2 were almost the same as those of Example 1 and that the sound insulation performance was improved.

[0034]

As described above, in the automobile floor carpet of the present invention, a cushioning material made of a polyester non-woven fabric having relatively large fibers and a repulsive force is provided on a portion on which an occupant is loaded, that is, on the floor carpet mounting floor surface. The cushioning material made of polyester non-woven fabric with relatively small fineness and good sound absorbing performance is used on the upper and side parts of the center tunnel where there are many openings due to the operation system device. Since they are formed by overlapping without a gap, non-woven fabrics with optimal fiber blends will be set for the part that requires repulsive force and the part that requires sound absorption performance, which makes it possible to improve sound vibration performance with lightweight. The effect is obtained.

In a preferred embodiment of the present invention, two types of polyester non-woven fabrics having different blends are integrated in advance to form a block-shaped non-woven fabric raw material, so that it is easy to handle in the molding step. .

[Brief description of drawings]

1A is a perspective view of an automobile floor carpet of the present invention, FIG. 1B is a sectional view taken along the line AA ′ of FIG. 1A, and FIG. FIG. 6 is a perspective view of the cushioning material, and a portion surrounded by a circle shows a state where the cushioning materials are overlapped with each other without a gap.

FIG. 2 is a schematic view showing a production example of a block-shaped nonwoven fabric raw material in Example 2.

FIG. 3 is a schematic view showing a production example of a block-shaped nonwoven fabric raw material in Example 3.

4 (A), (B) and (C) are molding process diagrams showing the production of the cushioning material for the floor carpet of the present invention.

FIG. 5 is a graph showing the sound insulation performance of car floor carpets obtained in Examples of the present invention and Comparative Example.

FIG. 6 is a cross-sectional view showing a state in which the automobile floor carpet of the present invention is attached to a floor panel.

[Explanation of symbols]

1 Cushioning material on the part where load is applied 2 Buffer material for the center tunnel 3 backing materials 4 Carpet skin material 5 Web supply port 6 conveyor 7 Block-shaped non-woven fabric roll 8 Block-shaped non-woven fabric roll 9 Upper mold for cushioning material molding 10 Lower mold for cushioning material molding 11 The part where the cushioning material is compressed 12 cross members 13 floor panels 14 seat legs Part where the cushioning material has a relief shape (compression) X Integral block-shaped nonwoven fabric roll Y Block-shaped non-woven fabric roll Z Integrated block non-woven fabric

Continuation of the front page (56) Reference JP-A-7-205705 (JP, A) JP-A-8-318774 (JP, A) JP-A-7-228177 (JP, A) JP-A-61-105242 (JP , A) JP 8-108500 (JP, A) JP 8-104164 (JP, A) JP 7-223478 (JP, A) JP 8-108810 (JP, A) JP 8-188951 (JP, A) JP-A-2-242960 (JP, A) JP-A-1-239150 (JP, A) JP-A-9-176948 (JP, A) Actual development Sho-58-168929 (JP, A) U) Actual development Sho 62-152842 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) B60N 3/00-5/00 B60R 13/01-13/04 B60R 13/08 A47G 27/00-27/06 D04H 1/00-18/00

Claims (10)

(57) [Claims] 1. An automobile floor carpet comprising a non-woven fabric made of polyester short fibers hot-pressed with a cushioning material present between a floor panel on which a floor carpet is mounted and upper and side surfaces of a center tunnel and a floor carpet skin. Provided on the floor surface on which the floor carpet is mounted and on the upper surface and the side surface of the center tunnel are cushioning materials made of at least two kinds of polyester non-woven fabrics having different fiber blends and / or areal weights (area densities), and the respective cushioning materials are spaced from each other. An automobile floor carpet characterized by being molded without overlapping. 2. The floor carpet for an automobile according to claim 1, wherein a plurality of cushioning materials made of at least two types of polyester non-woven fabric are provided so as to be parallel to the side members. 3. The automobile floor carpet according to claim 1, wherein at least two types of polyester short-fiber non-woven fabrics constituting the respective cushioning materials have different average fineness. 4. The cushioning material provided on the floor surface on which the floor carpet is mounted has an average fineness of 4 to 40 denier and has an average apparent density of 0, excluding end portions, stop points, and special parts of escape shape of other parts. The cushioning material made of polyester short fiber non-woven fabric of 0.02 to 0.1 g / cm ³ and provided on the upper and side surfaces of the center tunnel has an average fineness of 1.5 to 3 denier and has the above-mentioned special average density. The floor carpet for an automobile according to any one of claims 1 to 3, which is made of a non-woven fabric made of polyester short fibers having a weight ratio of 0.02 to 0.1 g / cm ³ except for a portion thereof. 5. As a fiber mixture of a cushioning material on a floor surface for mounting a floor carpet, a solid or hollow side-by-side type conjugate fiber having a matrix fiber of 5 to 20 denier and a core sheath having a binder fiber of 2 to 15 denier. Type low contact point fibers, each of which has a blending ratio of 70 to 90% by weight of matrix fibers and 10 to 30% by weight of binder fibers, while the blending ratio of the buffer material of the center tunnel is: The matrix fiber A is a fiber having 1.5 to 3 denier, the matrix fiber B is 4 to 8 denier, and the binder fiber is 1.5 to 2 denier, which is a core-sheath type low melting point fiber. And matrix fiber B total 70 to 90% by weight, matrix fiber B is at least 2
It contains 0% by weight or more and contains 10 to 3 binder fibers.
A range of 0% by weight, characterized in that
The floor carpet for vehicles according to any one of 1. 6. A crystalline melting point polyester, wherein at least 10% of the 10 to 30% by weight of the binder fiber used as the cushioning material on the floor surface of the floor carpet is a crystalline melting point polyester. The floor carpet for vehicles according to any one of 1. 7. The cushioning material according to claim 1, wherein at least three card cross layers or air lays are used, and the web is dropped from the web supply port onto the conveyor without any gaps. An automotive floor carpet according to any one of claims 1 to 5, characterized in that an integrated non-woven fabric raw material having a different composition and / or basis weight in the width direction is used. 8. While feeding a block-shaped non-woven fabric raw material obtained by heat-treating a web to a conveyor, another type of polyester fiber having a different composition and / or basis weight is further provided on the conveyor from the web supply port to form a gap between the webs. 6. An integrated non-woven fabric raw material having a different composition and / or basis weight in the width direction obtained by dropping without use is used as a cushioning material. Car floor carpet. 9. A method for manufacturing an automobile floor carpet comprising the steps of: (1) a web of polyester fibers A constituting a cushioning material to be provided on a floor surface on which a floor carpet is mounted; a top surface of a center tunnel; Polyester fiber B constituting a cushioning material to be provided on the side surface
After laminating each of the webs using a card cross layer or an air lay, the web is heat-treated at a temperature of 180 to 210 ° C. to form a block-shaped non-woven fabric raw material. The non-woven fabric originals are arranged with a space between each other, and block-shaped non-woven fabric originals corresponding to the top and side surfaces of the center tunnel are
The block-shaped non-woven fabric raw material corresponding to the floor surface on which the floor carpet is mounted is set without gaps, and (3) the set block-shaped non-woven fabric raw material is heated to a temperature of up to 200 ° C., and then press-molded. The manufacturing method, wherein the cushioning material obtained is obtained, and then the cushioning material obtained in step (3) and the floor carpet skin material are adhered to obtain a floor carpet for automobile. 10. A method of manufacturing an automobile floor carpet comprising the steps of: (1) a web of polyester fibers A constituting a cushioning material to be provided on a floor surface on which a floor carpet is mounted, a card cloth layer or After stacking using the air lay, heat treatment is performed at a temperature of 180 to 210 ° C. to form a block-shaped non-woven fabric raw material, and the non-woven fabric raw material obtained in (2) step (1) is supplied to the conveyor at intervals. While arranging webs of other polyester fibers having different blending and / or basis weight within the above-mentioned intervals without any gap, heat treatment is performed at a temperature of 180 to 210 ° C to obtain an integrated block-shaped nonwoven fabric raw material (3 ) The block-shaped non-woven fabric raw material obtained in step (2) is heated to a temperature of up to 200 ° C., and then press-molded to obtain a cushioning material, and then (4) the cushioning material obtained in step (3) And the floor carpet skin material are bonded together to obtain an automobile floor carpet.