JP3790493B2 - Car mat manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention, floor mat is laid on the floor of an automobile, a method of manufacturing a Kama' bets optional mat which is laid on the floor mat.
[0002]
[Prior art]
Generally, as a car mat, PVC (polyvinyl chloride), SBS (styrene-butadiene-styrene copolymer), etc. are provided on the back side of a skin layer made of a cut pile or loop pile tuft carpet or a fiber web needle punch carpet. A material obtained by melting and bonding a backing layer made of a synthetic resin is known.
[0003]
By the way, since the backing layer melt-bonded to the back side of the skin layer is non-breathable, the car mat has a problem that the sound bounces off the backing layer, and the bounced sound spreads in the vehicle to reduce the quiet performance in the vehicle. was there.
[0004]
Therefore, recently, a sound-absorbing layer composed of a breathable fiber structure such as a needle punched nonwoven fabric is integrally joined to the back side of the skin layer in place of the non-breathable backing layer, and this sound-absorbing layer is used for interior of the vehicle The noise is absorbed. The sound-absorbing layer is formed by mixing thermoplastic short fibers having a high melting point with thermoplastic short fibers having a lower melting point at a predetermined ratio, and carding the mixed fibers to form a sheet-like short fiber web. After needle punching the short fiber web, it is formed into a breathable fiber structure in which low-melting thermoplastic short fibers are welded and solidified to high-melting thermoplastic short fibers by heat treatment to give a certain degree of rigidity. ing.
[0005]
2. Description of the Related Art Conventionally, in this type of car mat, as shown in FIG. 2, a skin layer 11 and a sound absorbing layer 12 are melt-bonded by a powder layer 13 made of a hot melt powder of a thermoplastic resin. That is, hot melt powder is spread almost evenly on the upper surface, which is the bonding surface of the sound absorbing layer 12, and the hot melt powder is irradiated with far infrared rays to melt the hot melt powder, and the hot melt powder is cooled. Prior to solidification, the skin layer 11 is laminated thereon, whereby the skin layer 11 and the sound absorbing layer 12 are melt-bonded by the powder layer 13.
[0006]
[Problems to be solved by the invention]
In the conventional car mat, since the skin layer 11 and the sound absorbing layer 12 are melt-bonded by the powder layer 13, the heat treatment for welding and solidifying the thermoplastic short fibers having a low melting point of the sound absorbing layer 12 to the thermoplastic short fibers having a high melting point. A heat treatment step for melting and joining the skin layer 11 and the sound absorbing layer 12 is necessary separately from the step. For this reason, there is a problem that not only the processing efficiency cannot be improved due to an increase in the number of processing steps, but the manufacturing cost increases because the hot melt powder is expensive.
[0007]
In view of the above-described conventional problems, an object of the present invention is to provide a method for manufacturing a car mat that does not involve an increase in processing man-hours and manufacturing costs.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the present invention mixes a skin layer composed of a tuft carpet or a needle punch carpet and two or more fibers having different melting points, and welds and solidifies the low melting point fibers to the high melting point fibers. in car mat manufacturing method comprising a backing layer made of a fibrous structure having gas permeability that is applied above a certain rigidity, and a bonding layer for integrally bonding the backing layer and the skin layer Te Separately, a mixed fiber of a high melting point fiber and a low melting point fiber for a sound absorbing layer is formed on a sheet-like fiber web. A sheet-like fiber web formed of fibers is laminated on the fiber web for the sound absorbing layer, and the laminated material is used for the low melting point fiber for the sound absorbing layer and the bonding layer. Heating at a temperature above the melting point of the melting point fiber and below the melting point of the high melting point fiber for the sound absorbing layer to melt the low melting point fiber for the sound absorbing layer and the low melting point fiber for the bonding layer, thereby The low melting point fibers of the bonding layer are completely melted, and the skin layer is laminated and cooled on the fiber web for the bonding layer in the total molten state, thereby cooling the low melting point fibers for the sound absorbing layer with a high melting point. A method for producing a car mat, characterized in that the sound absorbing layer is formed by welding and solidifying to a fiber, and the skin layer and the sound absorbing layer are integrally bonded by solidifying the low-melting point fiber for the bonding layer. provide.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0010]
FIG. 1 is a partially enlarged longitudinal sectional view showing a schematic configuration of a car mat manufactured according to the present invention. 1 is a skin layer, 2 is a sound absorbing layer melt-bonded to the back side of the skin layer 1 by a bonding layer 3. ing.
[0011]
The skin layer 1 is constituted by a cut pile or loop pile tuft carpet or a fiber web needle punch carpet. In this embodiment, a cut pile tufted carpet is used.
[0012]
The sound absorbing layer 2 is a fiber structure formed by mixing two or more fibers having different melting points, for example, a high melting point thermoplastic short fiber having a melting point set to 260 ° C., such as a polyester short fiber (regular PET). Short fiber), polypropylene short fiber (PP short fiber), acrylic, etc., low melting point thermoplastic short fiber set at a lower melting point, such as modified polyester short fiber (modified PET short fiber), polyethylene short Fiber (PE short fiber) and PP short fiber are mixed at a ratio of, for example, about 5 to 80%, and the mixed fiber is carded to form a sheet-like short fiber web. A needle punch is formed on the short fiber web. It is formed by applying.
[0013]
The bonding layer 3 is a fiber structure mainly formed of all-melting type polyethylene short fibers or polypropylene short fibers, for example, PE short fibers or PP short fibers which are low melting thermoplastic short fibers having a melting point set to 120 ° C. The fiber is carded to form a sheet-like short fiber web.
[0014]
The car mat manufactured according to the present invention has the above-described configuration. In order to manufacture this car mat, a mixed short fiber of a high melting point thermoplastic short fiber and a low melting point thermoplastic short fiber to be the sound absorbing layer 2 is mixed with a card machine. Separately, a sheet-like short fiber web is formed, and separately, a low-melting point thermoplastic short fiber to be the bonding layer 3 is carded by a card machine to form a sheet-like short fiber web. 2 is laminated on a short fiber web to be 2, and the laminated product is needle punched by a needle punch machine to form a web laminate. In this case, the short fiber web to be the sound absorbing layer 2 and the short fiber web to be the bonding layer 3 are laminated and needle punched together, but the short fiber web to be the sound absorbing layer 2 and the short fiber to be the bonding layer 3 The webs may be laminated after needle punching separately. However, it is more efficient to laminate the short fiber web to be the sound absorbing layer 2 and the short fiber web to be the bonding layer 3 and perform needle punching together, because the needle punching is performed once.
[0015]
Next, the formed web laminate is sent to a suction type heating device by a conveying means such as a conveyor, and the web laminate is heated by this heating device. In this case, the low melting point thermoplastic short fibers of the short fiber web to be the sound absorbing layer 2 and the low melting point thermoplastic short fibers of the short fiber web to be the bonding layer 3 and the high melting point heat of the sound absorbing layer 2 are used. The web laminate is heated at a temperature below the melting point of the short plastic fibers. In this suction type heating device, hot web is forced to pass through the web laminate by heating hot air from above or below the heating device to heat the web laminate. With this heating, the low-melting thermoplastic short fibers of the short fiber web that becomes the sound absorbing layer 2 are melted in the web laminate, and the low melting thermoplastic short fibers of the short fiber web that becomes the bonding layer 3 are melted.
[0016]
Next, immediately after the heated web laminate comes out of the heating device, the skin layer 1 is placed on the short fiber web that becomes the joining layer 3, and this is used as the joining layer 3 of the web laminate by the pressing roller. Crimp to fiber web.
[0017]
Finally, by cooling the skin layer 1 and the web laminate by an appropriate cooling means, the melted low-melting thermoplastic short fibers of the short-fiber web to be the sound-absorbing layer 2 are welded and solidified to the high-melting thermoplastic short fibers. Thus, the sound absorbing layer 2 having a certain level of rigidity is formed, and the low-melting-point thermoplastic short fibers melted in the short fiber web to be the bonding layer 3 are solidified to bond the skin layer 1 and the sound absorbing layer 2 together. A car mat melt bonded by layer 3 is produced.
[0018]
As described above, the car mat manufactured according to the present invention is melted by the bonding layer 3 composed of a fiber structure in which the skin layer 1 and the sound absorbing layer 2 are mainly formed of polyethylene short fibers or polypropylene short fibers of the total melting type. Since they are joined, the skin layer 1 and the sound absorbing layer 2 can be melt-bonded at the same time during the heat treatment step in which the thermoplastic short fibers having a low melting point of the sound absorbing layer 2 are welded and solidified to the thermoplastic short fibers having a high melting point. That is, by laminating the fiber structure to be the bonding layer 3 on the fiber structure to be the sound absorbing layer 2 and heating, the thermoplastic short fibers having a low melting point of the sound absorbing layer 2 are welded and solidified to the thermoplastic short fibers having a high melting point. At the same time, the skin layer 1 and the sound absorbing layer 2 can be melt-bonded simultaneously. Therefore, compared with the conventional car mat, the heat treatment process for melting and joining the skin layer 1 and the sound absorbing layer 2 can be omitted, and the manufacturing cost can be reduced by reducing the processing steps and making expensive hot melt powder unnecessary. be able to.
[0019]
In the above embodiment, the web laminate is heated by forcibly passing hot air through the web laminate by a suction-type heating device. The web laminate may be heated or heated with water vapor or the like.
[0020]
【The invention's effect】
As described above, the carpet manufactured according to the present invention mainly comprises a skin layer composed of a tuft carpet or a needle punch carpet, and a sound absorbing layer composed of a fiber structure having air permeability. Since it is melt-bonded by a bonding layer composed of a short fiber or a polypropylene short fiber and has a breathable fiber structure, the skin layer and the sound absorbing layer can be bonded without using expensive hot melt powder, It is possible to manufacture a car mat with good sound absorption performance at low cost.
[0021]
In addition, the car mat manufacturing method according to the present invention includes a fiber structure that is a sound absorbing layer in which a mixed fiber of high melting point fibers and low melting point fibers is formed on a sheet-like fiber web, and a main melt type polyethylene short. By laminating and heating a low-melting fiber made of fibers or polypropylene short fibers into a sheet-like fiber web, which is a bonding layer, and heating, the skin absorbing layer and the sound absorbing layer are simultaneously formed. Since the joining is performed integrally, the conventional heat treatment step for joining the skin layer and the sound absorbing layer can be omitted, and the omission of the heat treatment step reduces the number of processing steps, thereby reducing the manufacturing cost. be able to.
[Brief description of the drawings]
FIG. 1 is a partially enlarged longitudinal sectional view showing a schematic configuration of a car mat manufactured according to the present invention.
FIG. 2 is a partially enlarged longitudinal sectional view showing a schematic configuration of a conventional car mat.
[Explanation of symbols]
1 Skin layer 2 Sound absorbing layer 3 Bonding layer

Claims (1)

A skin layer composed of tufted carpet or needle punched carpet,
A sound-absorbing layer composed of a breathable fiber structure in which two or more fibers having different melting points are mixed, and a low melting point fiber is welded and solidified to a high melting point fiber to give a certain level of rigidity;
A method of manufacturing a car mat comprising a bonding layer for integrally bonding the skin layer and the sound absorbing layer,
Forming a mixed fiber of high melting point fibers and low melting point fibers for the sound absorbing layer into a sheet-like fiber web;
Separately from this, a sheet-shaped fiber web formed of a total melt type polyethylene short fiber or polypropylene short fiber for the bonding layer is laminated on the sound absorbing layer fiber web,
The laminated layer is heated at a temperature equal to or higher than the melting point of the low melting point fiber for the sound absorbing layer and the low melting point fiber for the bonding layer and lower than the melting point of the high melting point fiber for the sound absorbing layer. Melting the low melting point fiber for use and the low melting point fiber for the joining layer, thereby melting the low melting point fiber of the joining layer completely
In this fully melted state, the skin layer is laminated on the fiber web for the bonding layer and cooled to weld and solidify the low melting point fibers for the sound absorbing layer to the high melting point fibers to form the sound absorbing layer. In addition, the method for producing a car mat is characterized in that the low melting point fiber for the bonding layer is solidified to integrally bond the skin layer and the sound absorbing layer.

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