JP3934216B2 - Automotive floor laying material and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a floor laying material that is molded into a shape according to a floor panel of an automobile and laid on the floor panel, and a manufacturing method thereof.
[0002]
[Prior art]
Conventionally, laying materials (tuft carpets, needle punch carpets, etc.) formed in a shape approximately in line with the floor panel are laid on the floor panel of an automobile interior, trunk or the like to decorate the interior. Moreover, a cushioning material such as felt is partially attached to the back surface of this type of laying material, and the feeling of laying is improved by interposing it between the floor panel.
Conventionally, a sheet having a relatively low melting point thermoplastic resin such as low density polyethylene resin or ethylene vinyl acetate resin is formed on the back surface of the laying material in order to form the shape along the floor panel where the laying material made of carpet or the like is laid. It was lined in the shape. The lining material with this type of backing is heated from the backing side with an infrared heater or the like, so that the backing becomes plasticized. By drawing with a mold, the required shape is obtained, and the backing is cooled and molded. The shape was fixed. Further, by placing a cushioning material such as felt in the molding die at the time of molding, the cushioning material was stuck to the plasticized backing at the same time as molding. (If a cushioning material with fluff, such as felt, is pressed on the lining in plastic state, the cushioning material is attached by the fuzz entering the lining.) However, in this case, a thermoplastic resin is applied to the entire back surface of the carpet. There was a problem that the weight of the laying material was considerably increased by applying the lining. (Sheet lining has a basis weight of 100 to 200 g / m ² or less, because the heat retention time is extremely reduced and the molding conditions are greatly limited, so it is not possible to reduce the weight by reducing the basis weight.) In addition, a large-capacity heater is required for heating the backing, and there is a problem of low energy efficiency due to radiation heating.
[0003]
Therefore, when there is a strong demand for weight reduction and energy saving, a laying material without a backing may be used. A web is formed with at least two types of fibers, one of these fibers is made into a thermoplastic resin fiber having a relatively low melting point, and the web is subjected to a needling treatment so that the fibers are entangled with each other. A dispersed nonwoven is obtained. When this non-woven fabric is heated to a temperature higher than the melting point of the low-melting fiber, plasticity is developed, and this can be drawn into a required shape to obtain a floor laying material.
[0004]
This laying material can be reduced in weight because there is no backing, and the energy efficiency of heating can be increased by adopting hot air heating for a breathable base material. However, since this laying material has no backing, it is impossible to attach the cushioning material at the same time as the laying material having the backing described above when the buffering material is to be attached to the back surface. It was necessary to take a step of attaching a cushioning material using an adhesive.
[0005]
[Problems to be solved by the invention]
In view of the above-mentioned problems, the present invention has a configuration of a laying material capable of adhering a cushioning material to the back surface at the same time as the molding, even in a nonwoven fabric type floor laying material formed including low-melting fibers, and A manufacturing method is provided.
[0006]
[Means for Solving the Problems]
The means of the present invention to solve the problems, a laying material laid on the floor panel is formed into a shape along the floor panel of a motor vehicle, viewed it contains a low melting point thermoplastic resin fibers, basis weight 300~2000g / m ^2, was applied as in at least a partial region of the back surface of the fibrous base material is breathable 0.1cc / cm 2 / ^s or more, does not inhibit breathability of the fibrous substrate, web-like or net Automotive floor laying material in which a cushioning material is stuck via a discontinuous backing of a thermoplastic resin in the form of powder, powder or bead , and a thermoplastic resin fiber having a low melting point as a method for producing the floor laying material And a step of obtaining a fibrous base material having a basis weight of 300 to 2000 g / m ² and an air permeability of 0.1 cc / cm ² / s or more by needling a web made of other fibers, and the obtained fiber Base Fibers discontinuous backing of web-like or net-like or powder-like or bead-like thermoplastic resin to at least a partial area which has been subjected the step of applying to not inhibit breathability of the fibrous base material, the lining of the back surface of A process of plasticizing the low-melting-point continuous fibers contained in the base material and the backing applied to the back surface, and drawing the fiber base material into the required shape and simultaneously plasticizing the backing material According to the manufacturing method of an automobile floor laying material comprising a step of stacking and sticking cushioning materials together. The automotive floor laying material of the present invention includes a thermoplastic resin fiber having a low melting point in a fibrous base material, and the low melting point fiber contained in the plastic base is heated to a desired shape by heating the base material. It can be drawn. At this time, it is preferable in terms of energy efficiency that the fibrous base material is heated by hot air heating utilizing the characteristics of the base material having air permeability. The discontinuous backing of the thermoplastic resin applied to the back surface of the fibrous base material does not impair the breathability of the base material due to the discontinuity, and the above-mentioned fiber base material molding process Is simultaneously plasticized by heating with hot air, and a cushioning material such as felt is placed on top of each other so that the cushioning material is adhered and integrated simultaneously with the formation of the fibrous base material.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described with reference to the drawings.
FIG. 1 is an external view of an automobile floor laying material to which the present invention is applied, and FIG. 2 shows the floor laying material of the present invention corresponding to the cross section along line AA of FIG.
The floor laying material 10 of the present invention is formed along the floor panel on which this laying material is laid, and is composed of a fibrous base material 11 and a cushioning material 12. The cushioning material is stuck to the back surface of the fibrous base material through a discontinuous backing 20 of thermoplastic resin.
The fibrous base material 11 is formed into a needle punched cloth by needling a web formed by mixing thermoplastic resin fibers having a low melting point and other fibers (having a higher melting point). The basis weight is 300 to 2000 g / m ² , and air permeability (0.1 cc / cm ² / s or more) necessary for hot air heating is maintained. The thermoplastic resin fiber having a low melting point is preferably a thermoplastic resin having a melting point of about 130 to 180 ° C., and a modified low melting point polyester fiber or a higher melting point (240) using the low melting point polyester component as a sheath structure. A conjugate fiber having a regular polyester of ˜260 ° C. as a core component is preferable. Polypropylene fibers and polyethylene fibers are also preferable. (Fiber length 10-120 mm, fineness 1.5-50 denier)
As other fibers to be combined with the low-melting fibers, fibers having a melting point of 200 ° C. or higher and non-thermoplastic fibers are preferable, and regular polyester fibers are suitable. The mixing ratio of the low melting point fiber to other fibers is suitably about 5 to 50% by weight.
The cushioning material 12 suitable for the present invention is preferably a felt-like material having fluff on the surface. Resin felt obtained by solidifying soot fibers with a phenol resin, synthetic felt formed with synthetic fibers having a relatively high melting point, and the like can be used. The cushioning material has a size that does not protrude at least beyond the fibrous base material, and may be a single piece or may be divided into a plurality of pieces.
The discontinuous backing 20 of the thermoplastic resin for adhering the cushioning material to the fibrous base material is made of a thermoplastic resin (130 to 180 ° C.) having a low melting point such as ethylene-vinyl acetate resin. , Net, powder, bead, etc. In either case, it has a discontinuity that does not impair the breathability of the fibrous base material. A basis weight of 30 g / m ² or more is suitable.
[0008]
Next, the suitable manufacturing method of this invention floor laying material is demonstrated based on FIGS.
(Formation process of fibrous base material)
As the raw material fibers, low-melting point thermoplastic resin fibers 11a serving as a binder and at least one other fiber 11b are weighed at a predetermined ratio and put into the fiber opening machine 30, the raw material fibers are unraveled and mixed uniformly. Next, the fibers are sent to the carding machine 40 where the fibers are gathered and formed into a web W formed by uniformly mixing the low melting point fibers. This web is passed through the needling device 50 and formed into a non-woven fabric N (having a basis weight of 300 to 2000 g / m ² and a thickness of ² to 10 mm) for being struck with a needle.
(Granting process of backing)
A discontinuous backing 20 of thermoplastic resin is applied to the back surface of the obtained nonwoven fabric. There are at least four preferred embodiments of this backing and backing method:
(A) First, a web-shaped backing 21 is applied. (Figure 3)
Continuously (or simultaneously) the needling in the step of forming the fibrous base material, a thermoplastic resin web corresponding to the backing is overlapped on the back surface of the fibrous base material, and then a slight needling is applied to the backing web. This is an embodiment in which the fibers are slightly entangled with the surface of the fibrous base material (not entering inside) and temporarily held.
(B) Secondly, there is a form of lining the net. (Not shown)
In this case, it is an embodiment in which a net-like backing previously formed in a separate process is placed on the back surface of the fibrous base material. Although there are various forms of this net, it is suitable that the mesh size is several millimeters to several tens of millimeters and the thickness of the fibers constituting the mesh is several millimeters. In order to temporarily hold the net-like backing on the fibrous base material, slight needling may be applied.
(C) Third, there is a form in which a backing is formed in a powder form. (Not shown)
This is a method of spraying thermoplastic resin powder corresponding to the backing from above while transporting the fibrous base material with a conveyor or the like with the back surface facing upward. The particle size of the powder is preferably several millimeters or less.
(D) Fourth, there is a form in which a bead-shaped backing is applied. (Not shown)
While conveying the fibrous base material with a conveyor or the like with the back side facing up, the thermoplastic resin to be lined is melted in a screw extruder, and multiple rows of bead-shaped resins are drawn from a die placed at the tip of the extruder. Extruded and continuously applied to the back surface of the fibrous base material. A suitable diameter of each bead is 2 to 10 mm.
[0009]
(Heating process, Fig. 4)
Heating for forming the fibrous base material is performed by hot air heating. The fibrous base material 11 provided with the backing 20 is conveyed into the heating furnace 60, hot air heated by the heating device 61 is introduced into the heating furnace via the plurality of pipes 62, and passes through the fibrous base material. Create a flow. The temperature of the hot air is high enough to plasticize the low-melting-point fibers contained in the fibrous base material and the backing 20 and does not affect other fibers of the fibrous base material (160 to 180). (C, 30-60 seconds).
(Molding, cushioning process, Fig. 5)
The heated fibrous base material is put into a press mold 70 having a shape along the floor panel and press-molded. At this time, the cushioning material 12 to be stuck in the mold is previously arranged, and the cushioning material is backed in a plastic state by overlapping the portion where the backing 20 of the fibrous base material is overlapped on the upper surface thereof. Thus, an automotive floor laying material having a cushioning material attached simultaneously with the formation of the fibrous base material is obtained.
【The invention's effect】
The automobile floor laying material of the present invention can be molded and laid in a shape along the floor panel of the automobile. Simultaneously with the molding, the buffer material can be bonded and integrated.
It is lightweight and can be manufactured efficiently.
[Brief description of the drawings]
FIG. 1 is an external view of an automobile floor laying material to which the present invention is applied, and FIG. 2 is a cross-sectional view of the floor laying material of the present invention corresponding to the cross section along line AA in FIG.
3 to 5 show a method for producing a floor laying material of the present invention, FIG. 3 shows a fiber base material formation and lining application step, FIG. 4 shows a heating step, FIG. 5 shows a laying material molding step, and FIG. The sticking process of a buffer material is shown.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Car floor laying material 11 ... Fiber base material 11a ... Low melting point thermoplastic resin fiber 11b ... Other fiber 12 ... Buffer material 20 ... No thermoplastic resin Continuous backing 21 ... web-like backing 30 ... spreader 40 ... carding machine 50 ... needling device 60 ... heating furnace 70 ... press mold W ... web

Claims (2)

A laying material laid on the floor panel is formed into a shape along the floor panel of a motor vehicle, viewed it contains a low melting point thermoplastic resin fibers, basis weight 300~2000g ^{/ m} 2, air permeability 0.1 cc / A web-like, net-like, powder-like, or bead-like thermoplastic , which is applied to at least a partial region of the back surface of the fibrous base material of cm ² / s or more so as not to inhibit the air permeability of the fibrous base material . A floor laying material for automobiles, characterized in that a cushioning material is stuck through a discontinuous backing of resin. A process of obtaining a fibrous base material having a basis weight of 300 to 2000 g / m ² and a breathability of 0.1 cc / cm ² / s or more by needling a low melting point thermoplastic resin fiber and a web made of other fibers. And a continuous backing of a web-like, net-like, powder-like or bead-like thermoplastic resin in at least a partial region of the back side of the obtained fibrous base material so as not to impair the breathability of the fibrous base material. A process of applying, heating the heated fiber base material with hot air to plasticize the low melting point fiber contained in the base material and the back of the fiber base material, and reducing the fiber base material to the required shape The method for producing an automotive floor laying material according to claim 1, further comprising a step of stacking and adhering a cushioning material on a plasticized backing simultaneously with molding.

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