JP6005914B2 - Method for manufacturing cushioning material for vehicle provided on vehicle body panel side of floor carpet - Google Patents

Description

The present invention relates to the production how the vehicle cushions provided on the vehicle body panel side of the floor carpet.

  Various interior materials are laid on the body panels of automobiles in order to enhance design and luxury. A floor carpet is usually laid as an interior material on the upper side of the vehicle body panel from the substantially flat floor panel to the toe board panel rising upward.

  In order to improve the cushioning property of the floor carpet, an underlay is also provided on the back surface of the floor carpet. The underlay fills the space between the floor carpet and the uneven floor panel to ensure the flatness of the surface of the floor carpet, and serves as a raising material that supports the floor carpet. Contributes to sound insulation performance. For the underlay, for example, felt type (synthetic felt or repellent felt), urethane type (molded by foaming reaction of urethane raw material, chip urethane bonded with binder), or resin particle foam was molded. Products, and those that combine recycled waste materials.

  FIG. 16 shows an end surface when a floor carpet 910 according to a conventional example is cut along a vertical surface along the longitudinal direction of the automobile. The floor carpet 910 is formed by pasting a flat felt 913 on the back surface 912 of a press-molded carpet body 911. The felt 913 is defibrated with a defibrator, fed to a feeder, blended, passed through a card machine to form a fiber fleece, and the fiber fleece is polymerized by a layer to form a multi-layer, such as needling The fiber is entangled, formed into a required thickness by press molding, and cut into a required size. In the felt 913 formed in this manner, the fibers 914 constituting the felt 913 are oriented substantially parallel to the felt surface, that is, the back surface 912 of the carpet body.

Japanese Utility Model Publication No. 62-162136

The underlay of the floor carpet is required to have rigidity for suppressing deformation. However, when the amount of the underlay is increased to improve the rigidity, the weight and cost of the underlay increase.
Further, the constituent fibers of the underlay provided on the floor carpet described above are oriented in a direction perpendicular to the thickness direction, that is, a direction along the back surface of the carpet body. For this reason, even if the underlay is press-molded, the thickness of the underlay cannot be partially changed, and the strength cannot be sufficiently improved.

  In addition, since the floor carpet of patent document 1 is not provided with the underlay, it does not lead to the solution of the subject mentioned above.

In view of the above, the present invention has an object to provide a vehicle floor carpet in which the strength of a required portion is improved without increasing the weight of a cushioning material.

In order to achieve the above object, the present invention provides a vehicle cushioning material provided on a vehicle body panel side of a floor carpet.
By performing press molding that compresses in the thickness direction on the fiber structure in which the webs are repeatedly laminated and the fibers are oriented in the thickness direction, a convex rib is provided between the general portion and the compression portion, and the web Including a step of forming a reinforcing portion that is bent in the web lamination direction and has increased rigidity with respect to the general portion,
In this step, the longitudinal direction of the convex rib along the floor carpet is arranged in the width direction of the web, so that the longitudinal direction of the convex rib along the floor carpet is directed in the web laminating direction. Compared with the case where it arranges, the angle | corner of the standup | rising part of the root part with respect to the said compression part is sharpened .

The reinforcement part formed in the buffer material is formed with a reinforcement part in which the web is bent in the lamination direction of the web by press molding of the fiber structure. Thereby, the intensity | strength of a required part improves, without the weight of a shock absorbing material increasing. Moreover, the aspect mentioned above can make a convex rib sharp shape.
Further, the present invention provides a vehicle cushioning material provided on the vehicle body panel side of the floor carpet,
By performing press molding that compresses in the thickness direction on the fiber structure in which the webs are repeatedly laminated and the fibers are oriented in the thickness direction, a convex rib is provided between the general portion and the compression portion, and the web Including a step of forming a reinforcing portion that is bent in the web lamination direction and has increased rigidity with respect to the general portion,
In the step, the longitudinal direction of the convex rib along the floor carpet is arranged in the web laminating direction so that the longitudinal direction of the convex rib along the floor carpet is oriented in the width direction of the web. Compared with the case where it arrange | positions, the corner | angular part of the standup | rising part of the root part with respect to the said compression part is rounded .
The reinforcement part formed in the buffer material is formed with a reinforcement part in which the web is bent in the lamination direction of the web by press molding of the fiber structure. Thereby, the intensity | strength of a required part improves, without the weight of a shock absorbing material increasing. Moreover, the aspect mentioned above can make a convex rib into a broad shape.
Here, the plurality of webs in the reinforcing portion may be bent in the same direction in the stacking direction, or the web in the reinforcing portion may be bent at the first and second bent portions in different directions.

Further , the fibers of the fiber structure being oriented in the thickness direction means that the arrangement direction of the fibers is relatively aligned in a direction orthogonal to the front surface and the back surface of the buffer material, and the fibers are thicker. Including having a folded portion for orientation in the direction. Since the fibers constituting the fiber structure may be bent, the fibers of the fiber structure are oriented in the thickness direction. This means that straight fibers are arranged in parallel in the thickness direction of the fiber structure. Does not mean.
As described above, the fiber structure in which the fibers are oriented in the thickness direction has a corrugated fiber structure in which the web is repeatedly folded in the thickness direction, and the corrugated fiber structure is divided into two in the middle of the thickness direction. Examples include a structure in which webs are repeatedly laminated, such as a fiber structure obtained and a fiber structure in which a folded portion of the corrugated fiber structure is cut.
The fiber constituting the fiber structure may be a single type of fiber or a combination of two or more types of fibers, such as a combination of a main fiber and an adhesive fiber.

  The convex rib should just be a site | part protruded in the thickness direction rather than the surrounding compression part so that the rigidity of a reinforcement part may be improved with respect to a general part. The web in the convex rib may be bent in the laminating direction of the web. Further, a plurality of webs in the convex rib may be bent in the same direction in the laminating direction, and the webs in the convex rib are mutually connected. You may bend in the 1st and 2nd bending part of a different direction. On the other hand, the case where the web in the convex rib is not bent is also included in the invention.

In the invention which concerns on Claim 1 , the intensity | strength of a required part can be improved, without increasing the weight of a shock absorbing material, and a convex rib can be made into a sharp shape.
In the invention which concerns on Claim 2 , the intensity | strength of a required part can be improved without increasing the weight of a shock absorbing material, and a convex rib can be made into a broad shape.

1 is a perspective view illustrating an appearance of a floor carpet 10 (vehicle interior material) 10 according to an embodiment of the present invention on a vehicle compartment SP1 side. It is a figure which illustrates the principal part of a vertical end surface when floor carpet 10 is cut along with the vehicle body panel 80 along the vehicle width direction. 1 is a perspective view illustrating a main part of a back surface shape of a floor carpet 10 as an example. It is a figure which illustrates a perpendicular | vertical end surface when the floor carpet 10 is cut | disconnected in the position corresponded to A1 of FIG. FIG. 4 is a side view illustrating the main part of the fiber structure 40 with the folded portion 47 left. (A) is a perspective view illustrating the main part of the fiber structure 40 with the folded part 47 left, and (b) is a perspective view illustrating the main part of the fiber structure 41 with the folded part 47 cut away. (A) is a bottom view illustrating the main part of the underlay 50 in which the longitudinal direction of the convex rib 56 is oriented in the width direction D2 of the web M1, and (b) is the longitudinal direction of the convex rib 56 in the laminating direction D1 of the web M1. It is a bottom view which illustrates the principal part of the underlay 50 which faced. (A) is a figure which illustrates the perpendicular | vertical end surface of the floor carpet 10 which orient | assigned the longitudinal direction of the convex rib 56 to the width direction D2 of the web M1, (b) orient | assigns the longitudinal direction of the convex rib 56 to the lamination direction D1 of the web M1. FIG. 3 is a diagram illustrating a vertical end surface of the floor carpet 10. (A)-(c) is a vertical end view which illustrates the direction of the web M1 in the convex rib 56. FIG. (A)-(c) is a vertical end elevation which illustrates the direction of the web M1 before compression. (A)-(c) is a vertical end view which illustrates the direction of the web M1 in the convex rib 56. FIG. 3 is a block diagram schematically illustrating a method for manufacturing the floor carpet 10. FIG. 3 is a vertical end view for explaining an example of a method for manufacturing the floor carpet 10. FIG. (A), (b) is a figure for illustrating the evaluation method of the rigidity of the floor carpet 10. FIG. 5 is a diagram illustrating a bending elastic gradient with respect to the width of a convex rib 56. FIG. It is a figure which shows the end surface when the floor carpet 910 which concerns on a prior art example is cut | disconnected by the vertical surface along the front-back direction of a motor vehicle.

  Embodiments of the present invention will be described below. Of course, the embodiments described below are merely illustrative of the present invention.

(1) Configuration of vehicle interior material having cushioning material:
FIGS. 1-8 has shown the example which applied the interior material for vehicles which concerns on this invention to the floor carpet for motor vehicles. In the figure, FRONT represents the front and REAR represents the rear. In the end view of FIG. 4, hatching indicating the end surface of the underlay (vehicle cushioning material) 50 is omitted.
A floor carpet 10 shown in FIG. 1 includes a substantially flat floor panel (a kind of vehicle body panel) constituting the floor surface of the vehicle body, a toe board panel (a kind of vehicle body panel) that rises upward from the floor panel surface at the front of the passenger compartment, It is set as the interior material for vehicles mounted on the above. A tunnel portion that bulges upward and extends back and forth is formed at the center of the floor panel and toe board panel in the vehicle width direction. The edge of the vehicle body panel 80 shown in FIG. 2 in the vehicle width direction rises outward in the vehicle width direction. The floor carpet 10 is laid on the vehicle compartment SP1 side of the vehicle body panel 80 and decorates the passenger compartment. The floor carpet 10 is formed in a three-dimensional shape so as to avoid protrusions such as a console and a rocker panel, and a part thereof along these standing walls.

  The basic portion of the floor carpet 10 is composed of a carpet layer (design layer) 30 and an underlay (buffer material layer) 50. The carpet layer 30 has an uneven shape 31 on the side of the passenger compartment SP1 and is disposed facing the passenger compartment SP1. The underlay 50 has an uneven shape 61 on the vehicle body panel 80 side, and is disposed facing the vehicle body panel 80. The floor carpet 10 is molded with a carpet layer 30 in which an uneven shape 31 on the side of the vehicle compartment SP1 is formed by press-molding a carpet body (design material) 20 (see FIG. 13) before molding to be the carpet layer 30. At least the underlay 50 on which the concave-convex shape 61 on the vehicle body panel 80 side is formed by pressing the previous fiber structure 40 is laminated and integrated. In the underlay 50 shown in FIG. 2, the design layer side surface 50 a on the front side is bonded to the carpet layer 10, the panel side surface 50 b on the back side faces the vehicle body panel 80, and a part of the panel side surface 50 b contacts the vehicle body panel 80. doing. As will be described in detail later, the fiber structure 40 is a structure in which fibers (45, 46) are oriented in the thickness direction D3 as shown in FIG.

The carpet layer 30 is a design layer that imparts characteristics such as designability, good tactile sensation, and wear resistance to the floor carpet 10. The carpet layer 30 shown in FIG. 2 is a tufted carpet having a back stitch of the pile 26 in the base layer 25, and a large number of piles 26 are raised on the vehicle compartment SP 1 side of the base layer 25. Of course, it is also possible to use a needle punch carpet or the like in which the nonwoven web is needled and the fibers are entangled to form a fluff on the surface.
For the pile yarn constituting the pile 26, polyolefin fibers such as PP fibers, polyamide fibers, polyester fibers such as PET (polyethylene terephthalate) fibers, synthetic fibers such as acrylic fibers, and the like can be used. .

  When the base layer 25 is formed of a base fabric, various nonwoven fabrics such as a spunbond nonwoven fabric, knitted fabrics of various fibers, and the like can be used for the base fabric. Synthetic fibers made of a polyolefin resin such as polyester, PP (polypropylene), and ethylene-propylene copolymer can be used for the fibers constituting the base fabric. The back of the base fabric (the surface on the underlay 50 side) may be lined. For this backing, a resin material (including an elastomer), a fiber material, or the like can be used. The resin material may be a material containing a resin, may be a material made of only a resin, or may be a material to which an additive is added. The resin constituting the resin material is preferably a synthetic resin, and particularly preferably a thermoplastic resin. This thermoplastic resin is preferably a thermoplastic resin having a low melting point (100 to 300 ° C.), and olefinic resins such as low density polyethylene, olefinic thermoplastic elastomers, ethylene vinyl acetate, and the like can be used. Moreover, the fiber which comprises the said fiber material can use the fiber of a synthetic resin (an elastomer is included), the fiber which added the additive to the synthetic resin, an inorganic fiber, etc., The fiber containing a thermoplastic fiber is preferable. . The resin constituting the thermoplastic fiber is preferably a low melting thermoplastic resin, and an olefin resin such as low density polyethylene, an olefin thermoplastic elastomer, ethylene vinyl acetate, or the like can be used.

As shown in FIG. 5 and FIG. 6A, the underlay (vehicle cushioning material) 50 is formed from a corrugated fiber structure 40 in which the web M1 is repeatedly folded in the thickness direction D3, and is lightweight. Moreover, it is bulky and has high sound absorption. The underlay 50 is formed from a fiber structure 40 including main fibers 45 and adhesive fibers (binders) 46, and is laminated in a range of 20% or more of the surface of the floor carpet 10 on the vehicle body panel 80 side. That is, the underlay 50 may be provided on the entire surface of the floor carpet 10 on the vehicle body panel 80 side, or may be provided on only a part of the surface of the floor carpet 10 on the vehicle body panel 80 side.
The thickness of the web M1 can be set to about 3 to 30% of the thickness of the fiber structure 40, for example. Further, the number of folded webs M1 (the number of folded peaks) can be, for example, about 1 to 5 times / 10 mm. When the number of turns is increased, the density is increased and the shape maintaining property and the load resistance as a raising material are increased. Since the number of web wraps is defined by the number of peaks, the number of webs per unit length is twice the number of wraps.

An apparatus for manufacturing a buffer material in which a continuous web is repeatedly folded into a waveform can be appropriately selected from various buffer material manufacturing apparatuses to which a known manufacturing method such as a STRUTO method is applied.
As the cushioning material manufacturing apparatus, for example, a textile wrap apparatus described in Japanese Patent Application Publication No. 2008-538130 and an apparatus that repeatedly turns a continuous web into a waveform by a gear are known.
As illustrated in FIG. 5, in each pleat M <b> 2 of the fiber structure 40 formed by the cushioning material manufacturing apparatus, the main fiber 45 and the adhesive fiber 46 are oriented in the thickness direction D <b> 3 except for the folded portion 47. . A part of the adhesive fiber 46 is melted and adheres to the main fibers 45 oriented in a wavy shape. Thus, a corrugated fiber structure 40 as shown in FIG. 6A is formed.

  In the formed fiber structure 40, the folded surface of each pleat M2 is aligned with the surface passing through the width direction D2 and the thickness direction D3 of the fiber structure 40, and the fibers (45, 46) are oriented in the thickness direction D3. . The front surface 40a and the back surface 40b in which the folded portions 47 are gathered are formed along the stacking direction D1 of the folds M2 (web M1). Here, the width direction of the fiber structure 40 is also the width direction of the web M1, and the web lamination direction D1, the web width direction D2, and the fiber structure thickness direction D3 are orthogonal to each other. Furthermore, in FIG. 5 etc., the extrusion direction of the fiber structure 40 by a buffer material manufacturing apparatus is shown as D11, and the opposite direction of this extrusion direction D11 is shown as D12. Here, the fibers (45, 46) being oriented in the thickness direction D3 means that the arrangement direction of the fibers (45, 46) is relatively aligned in a direction perpendicular to the front surface 40a and the back surface 40b. Meaning, including having a folded portion 47 of fibers.

  As the fibers (45, 46) for forming the fiber structure 40, fibers of synthetic resins (including elastomers), fibers obtained by adding additives to the synthetic resins, inorganic fibers, anti-fibers, and the like can be used. .

  The main fiber 45 can be a fiber of a thermoplastic resin (including a thermoplastic elastomer), a fiber obtained by adding an additive to a thermoplastic resin, an inorganic fiber, a repellent fiber, or the like. Polyester such as PET, PP, or the like Fibers made of thermoplastic resins such as polyolefin, polyamide, etc., fibers made of thermoplastic resins whose melting points are adjusted by modifying these thermoplastic resins, glass fibers, rayon fibers, anti-garment fibers, and further additives It is possible to use fibers made of the above materials, combinations of these fibers, and the like. The fiber diameter of the main fiber 45 can be about 5 to 60 μm, and the fiber length of the main fiber 45 can be about 10 to 100 mm. When the main fiber is a thermoplastic fiber, the melting point of the thermoplastic fiber can be set to a high melting point of about 250 to 260 ° C., for example.

The adhesive fiber 46 may be a fiber of a thermoplastic resin, a fiber obtained by adding an additive to a thermoplastic resin, or the like. A polyester such as PET, a polyolefin such as PP or PE (polyethylene), a heat such as polyamide. Fibers made of a plastic resin, fibers made of a thermoplastic resin whose melting point is adjusted by modifying these thermoplastic resins, fibers made of a material to which an additive has been added, and the like can be used. When the main fiber is a thermoplastic fiber, it is preferable to use a thermoplastic fiber having a melting point lower than that of the main fiber as the adhesive fiber. For example, when a fiber that is compatible with the main fiber is used as the adhesive fiber, the adhesion between the main fiber and the adhesive fiber is improved, and sufficient shape retention can be imparted to the underlay 50. The melting point of the adhesive fiber can be about 100 to 220 ° C.
Alternatively, a fiber having a core-sheath structure in which a fiber that can be used as the adhesive fiber is used as a sheath and the outer periphery of the core having a melting point higher than that of the sheath is surrounded by the sheath may be used as the adhesive fiber 46. In this case, a fiber that can be used for the main fiber 45 can be used for the core.

The fiber diameter of the adhesive fiber 46 can be about 10 to 45 μm, and the fiber length of the adhesive fiber 46 can be about 10 to 100 mm. The mixing ratio of the main fiber 45 and the adhesive fiber 46 can be about 30 to 95% by weight of the main fiber and about 5 to 70% by weight of the adhesive fiber.
In addition, you may form the fiber structure 40 using the binder which is not fibrous instead of an adhesive fiber.

Basis weight of the fibrous structure 40 is preferably in a range of 300 to 1500 g / m ^2, more preferably in the range of 500~800g / m ^2. Moreover, the thickness of the fiber structure 40 is suitably designed according to the vehicle shape applied between 10-50 mm. The density of the fibrous structure 40 is preferably in a range of 0.01~0.15g / m ^3, more preferably in the range of 0.02 to 0.08 g / m ^3.
Was measured compressive strength of the fiber structure 40, 2～15KPa when density is 0.01~0.15g / m ³ 1.5~40kPa next, at 0.02 to 0.08 g / m ³ It became. On the other hand, when the compressive strength of the conventional felt in which the fibers were oriented in the direction perpendicular to the thickness direction was measured, it was 2 kPa when the density was 0.055 g / m ³ . In addition, even in the case of a urethane chip mold that is heat-molded by spraying a binder such as isocyanate to waste materials such as urethane slab foam that has been conventionally used as a bulking material, when the density is 0.15 g / m ³ The compressive strength was 25 kPa. Thus, it can be seen that the fiber structure 40 has a low density and an equivalent compressive strength even when compared with a conventional product such as a urethane chip mold.
Here, the above-described compressive strength is a value obtained by measuring the compressive stress at 25% strain using a precision universal testing machine AG-500A manufactured by Shimadzu Corporation. The test conditions for this measurement are: the test piece size is 50 mm × 50 mm × thickness 20 mm, the compression speed is 10 mm / min, the entire compression area is not pre-compressed.

  The fiber structure for forming the underlay 50 only needs to have the fibers oriented in the thickness direction. Therefore, as shown in FIG. 6B, a fiber structure 41 in which the folded portion 47 of the front surface 40a and the back surface 40b of the fiber structure 40 described above is cut off may be used. Moreover, you may use the fiber structure obtained by dividing a waveform-shaped fiber structure into two in the middle of the thickness direction.

  As illustrated in FIGS. 2 to 4, the general portion 52 and the reinforcing portion 54 are formed by performing press molding for compressing the fiber structure 40 in the thickness direction D <b> 3. The reinforcing portion 54 is provided with a convex rib 56 between the compression portions 55 to enhance the rigidity of the general portion 52. Here, the rigidity comparison can use a bending elastic gradient according to the rigidity evaluation method of an example described later.

Since the floor carpet is formed in a concavo-convex shape, rigidity for suppressing deformation is required. In particular, the end portions of the floor carpet such as the side portion and the front edge portion are greatly raised, so that they are greatly stretched during molding and the strength tends to decrease. Accordingly, a reinforcing portion is provided at a required portion such as the vicinity of the end portion. The reinforcing portion 54 shown in FIG. 2 is formed at a rising portion in the vicinity of the end portion 11 in order to suppress deformation of the end portion 11 of the floor carpet 10.
A space of about 5 to 50 mm is often provided between the underlay 50 and the vehicle body panel 80 at the rising portion near the end portion 11 in order to install a harness or the like. As shown in FIG. It is often provided between the part and the standing wall part. When laying the underlay end floating from the vehicle body panel, it is necessary to prevent the floor carpet end from being lowered by its own weight. However, if a separate support member is installed at the end of the floor carpet or if the density of the underlay is increased, the cost of the floor carpet will increase. Increasing the density of the underlay also leads to a decrease in formability. Therefore, it is preferable to provide a reinforcing portion near the end of the floor carpet.

A compression portion 55 is formed by press molding of the fiber structure 40 at a required portion for increasing the rigidity, and a convex rib 56 is provided between the compression portions 55 so as to increase the rigidity with respect to the general portion 52. Thereby, the intensity | strength of a required part improves, without the weight of the shock absorbing material for vehicles increasing. In FIGS. 2 and 3, a plurality of concave compression portions 55 are arranged on the stepped portion of the rising portion near the floor carpet edge 11, and a substantially triangular convex rib 56 is formed between the compression portions 55. It has been shown. If the reinforcing portion 54 is configured in this way, the rigidity can be preferably increased, but the shape of the reinforcing portion 54 is not limited to this.
The thickness T2 (see FIG. 4) of the compression portion 55 is preferably thinner than the thickness T1 (see FIG. 2) of the general portion 52 from the viewpoint of increasing rigidity, and can be, for example, about 3 to 10 mm.

  The height H1 (see FIG. 4) of the convex rib 56 is made larger than the thickness T2 of the compression portion 55, and may be equal to or greater than the thickness T1 of the general portion 52. The direction of the convex rib 56 is such that the longitudinal direction along the carpet layer 30 (floor carpet 10) of the convex rib 56 is from the inside of the floor carpet 10 as illustrated in FIGS. Although the direction toward the outside is preferred, the longitudinal direction may be the direction along the periphery of the floor carpet 10 or the like. 7A and 7B, the left side is the inside and the right side is the outside, and the direction from the inside to the outside of the floor carpet 10 is the direction from the left to the right.

  The shape and number of the convex ribs 56 may be appropriately selected depending on the shape of the vehicle body panel on which the underlay is laid. When laying on a floor panel of a general passenger car, the length L1 of the convex rib in the longitudinal direction is, for example, 30 to 300 mm, the height H1 of the convex rib is, for example, 5-30 mm, and the convex rib width is, for example, about 3-30 mm. The number of convex ribs can be set to 1 to 10/1000 mm, for example. Further, the shape of the vertical cross section of the convex rib 56 in the longitudinal direction is preferably a shape in which the root portion 56b of the convex rib 56 is wider than the top portion 56a and has a rounded rounded corner shape, but is not limited to this, for example, the root portion 56b And the top 56a may have the same width. Furthermore, the width may be changed in the longitudinal direction of the convex rib, and the convex rib may be not only linear but also curved.

  The direction of the convex rib 56 with respect to the lamination direction D1 of the web M1 may be appropriately selected depending on the shape of the vehicle body panel on which the underlay is laid. 7A and 7B illustrate the main part of the underlay 50 by a bottom view. 8A and 8B illustrate a vertical end surface of the floor carpet 10. FIG.

  The convex ribs 56 shown in FIG. 7A are arranged with the longitudinal direction along the carpet layer 30 (floor carpet 10) facing the width direction D2 of the web M1. In this case, as shown to Fig.8 (a), since the corner | angular part of the root part 56b with respect to the compression part 55 and the corner | angular part 56a can be made comparatively sharp, a convex rib can be made into a sharp shape. Moreover, since the convex rib can be formed high (height H2), the rigidity of the reinforcing portion 54 is improved and the strength of the required portion is improved.

The convex rib 56 shown in FIG.7 (b) is arrange | positioned toward the lamination direction D1 of the web M1 in the longitudinal direction along the carpet layer 30 (floor carpet 10). In this case, as shown in FIG. 8B, the corners of the root portion 56b and the top portion 56a of the root portion 56b with respect to the compression portion 55 can be made relatively round, so that the convex rib can have a broad shape.
Of course, the reinforcing ribs may have a desired rigidity by adjusting the shape and height of the convex ribs by making the longitudinal direction of the convex ribs oblique to the web lamination direction D1.

  The direction of the web M1 in the convex rib 56 may be appropriately selected depending on the shape of the vehicle body panel on which the underlay is laid. 9A to 9C are vertical end views illustrating the orientation of the web M1 in the convex rib 56 when the longitudinal direction of the convex rib 56 is arranged in the web width direction D2. 10A to 10C are vertical end views illustrating the orientation of the web M1 in the fiber structure 40 before compression. In addition, illustration of the web M1 of the compression part 55 is abbreviate | omitted.

In the web M1 of the convex rib 56 shown in FIG. 9A, a bent portion M3 is formed which is bent in the fiber structure extrusion direction D11 which is one direction in the stacking direction D1 in the middle of the height. FIG. 10A illustrates the inclination of the web M1 suitable for forming the bent portion M3 shown in FIG. 9A in the fiber structure 40 before molding. Here, among the angles θ1 and θ2 formed by the web M1 with respect to the surface 40a of the fiber structure, an angle smaller than 90 degrees is represented by θ1, and an angle larger than 90 degrees is represented by θ2. That is, there is a relationship of 0 ° <θ1 <90 ° and θ2 = 180 ° −θ1. The angle θ1 is preferably 60 ° to 89 °.
Although not shown, a similar bent portion M3 may be formed in the compression portion 55 adjacent to the convex rib 56.

The web M1 of the convex rib 56 shown in FIG. 9B is formed with a bent portion M3 that is bent in the opposite direction D12 that is the other direction of the stacking direction D1 in the middle of the height. FIG. 10B illustrates the inclination of the web M1 suitable for forming the bent portion M3 shown in FIG. 9B in the fiber structure 40 before molding. Here, of the angles θ1 and θ2 formed by the web M1 with respect to the surface 40a of the fiber structure, an angle smaller than 90 degrees is represented by θ1, and an angle larger than 90 degrees is represented by θ2. The angle θ1 is preferably 60 ° to 89 °.
Although not shown, a similar bent portion M3 may be formed in the compression portion 55 adjacent to the convex rib 56.

Since the web M1 in the reinforcing portion 54 is bent in the web laminating direction D1, the cushioning property in the thickness direction D3, that is, the shape recoverability when compressed in the thickness direction D3 is increased. The followability to can be improved.
The bent portion M3 shown in FIGS. 9A and 9B is bent in a “<” shape or an “L” shape, but the bent portion may be smoothly bent.

  9A and 9B, the plurality of internal webs M1 are bent in the same direction in the stacking direction D1. Thereby, since the cushioning property in the thickness direction D3 is further enhanced, the followability to the vehicle body panel 80 can be further enhanced.

The web M1 of the convex rib 56 shown in FIG. 9C includes a first bent portion M4 bent in the fiber structure extrusion direction D11 in the middle of the height on the top side, and a height on the root side. Thus, a second bent portion M5 bent in the opposite direction D12 which is the other direction of the stacking direction D1 opposite to the first bent portion M4 is formed. Although the web M1 shown in FIG. 9C is bent in a double “<” shape or “Z” shape, the bending portion may be smoothly bent. FIG. 10C illustrates the orientation of the web M1 suitable for forming the bent portions (M4, M5) shown in FIG. 9C in the fiber structure 40 before molding. The angle θ1 formed by the web M1 with respect to the surface 40a of the fiber structure is preferably around 90 °.
Although not shown, the same bent portion (M4, M5) may be formed in the compression portion 55 adjacent to the convex rib 56.
Since the web M1 in the reinforcing portion 54 is bent in a plurality of stages, the cushioning property in the thickness direction D3, that is, the shape recovery property when compressed in the thickness direction D3 is further increased, and the body panel 80 is followed. The sex can be further enhanced.

  In the reinforcing portion 54 shown in FIG. 9C, the plurality of first bent portions M4 are bent in the same direction, and the plurality of second bent portions M5 are bent in the same direction. Thereby, since the cushioning property in the thickness direction D3 is further enhanced, the followability to the vehicle body panel 80 can be further enhanced.

The same applies to the case where the longitudinal direction of the convex rib 56 does not face the web width direction D2. 11A to 11C are vertical end views illustrating the orientation of the web M1 in the convex rib 56 when the longitudinal direction of the convex rib 56 is arranged in the web lamination direction D1.
In the web M1 of the convex rib 56 shown in FIG. 11A, a bent portion M3 that is bent in the fiber structure extrusion direction D11 is formed in the middle of the height. The web M1 of the convex rib 56 shown in FIG. 11B is formed with a bent portion M3 that is bent in the opposite direction D12 in the middle of the height. The web M1 of the convex rib 56 shown in FIG. 11 (c) has a first bent portion M4 bent in the extrusion direction D11 of the fiber structure in the middle of the height on the top side, and a middle of the height on the root side. And a second bent portion M5 bent in the opposite direction D12 is formed. Although not shown, the same bent portion (M3, M4, M5) may be formed in the compression portion 55 adjacent to the convex rib 56. In either case, the cushioning property in the thickness direction D3 is enhanced, so that the followability to the vehicle body panel 80 can be enhanced.

(2) Manufacturing method of vehicle interior material having cushioning material, and operation and effect:
FIG. 12 shows an example of a method for manufacturing the floor carpet (vehicle interior material) 10, and FIG. 13 shows an example of the press molding machine 200 with a vertical end face. In the manufacturing process of this floor carpet, the fabric roll 40 of the carpet body 20 before molding is placed in a predetermined place, and the fiber structure 40 before molding cut according to the size of the floor carpet 10 to be formed is cut cut place. It is started in the state that was put on.

First, the carpet body 20 is carried into the cutting machine from the fabric roll of the carpet body (step S1), and the carpet body 20 is cut to a standard size according to the size of the floor carpet 10 to be formed (step S2). The cut carpet main body 20 is carried into a heating machine such as an infrared heater and heated on both sides by radiant heating or the like, and the base layer 25 is softened (step S3). The carpet body 20 that has been softened by heating is carried into the press molding machine 200 (step S4).
On the other hand, the fiber structure 40 in the cut felt storage is carried into a heating machine such as a suction heater (hot air circulation heater) (step S5) and heated to a temperature slightly higher than the melting point of the adhesive fiber 46 by hot air heating or the like. Thus, the adhesive fiber 46 is softened (step S6). The heated fiber structure 40 is carried into the press molding machine 200 (step S7).

FIG. 13 is a vertical end view schematically showing a state in which the carpet body 20 and the fiber structure 40 are press-molded at the same time. In a press molding machine 200 shown in FIG. 13, an upper mold 212 and a lower mold 214 constituting a molding mold 210 are provided so as to be close to and away from each other. Here, the upper mold 212 is a mold having a molding surface 213 on the lower surface that matches the concave-convex shape 31 on the passenger compartment side of the floor carpet. The lower mold 214 is a mold that has a molding surface 215 on the upper surface that matches the concave-convex shape 61 on the vehicle body panel side of the floor carpet. In the heated carpet body 20 and the fiber structure 40, the carpet body 20 is disposed on the upper mold 212 side, and the fiber structure 40 is disposed on the lower mold 214 side. Of course, the base layer 25 of the carpet body and the front surface 40a (or back surface 40b) of the cushioning material are arranged to face each other, the pile 26 of the carpet body is arranged to face the upper mold 212, and the back surface 40b (or front surface) of the cushioning material. 40a) is arranged opposite the lower mold 214. When both molds 212 and 214 having the carpet body 20 and the fiber structure 40 disposed therebetween are brought close to each other, the floor carpet before trimming is press-molded (step S8).
When the fiber structure 40 includes a binder such as the adhesive fiber 46, the carpet layer 30 and the underlay 50 are formed by the binder of the fiber structure 40 even if the base layer 25 of the carpet body does not have an adhesive backing. Glue.

  The floor carpet before trimming is taken out of the press molding machine 200 after being cooled and carried into the outer periphery cutting machine (step S9). After demolding, the floor carpet before trimming is cut at the outer periphery by an outer cutter (step S10), and the floor carpet 10 is formed. The cutting method in Step S10 can be cutting with a cutting blade or water jet cutting. Further, the outer periphery may be cut by manual cutting using a cutter in a state where the floor carpet is press-molded with the molds 212 and 214 of step S8 close to each other, omitting step S9 and step S10. In the floor carpet 10 to be formed, the carpet layer 30 held in the uneven shape 31 and the underlay 50 held in the uneven shape 61 are laminated and integrated at least.

The manufacturing method of the floor carpet 10 is not limited to the above method. For example, in step S3, the carpet body 20 may be heated with a suction heater. Moreover, you may heat simultaneously with the suction heater in the state which accumulated the carpet main body 20 and the fiber structure 40. FIG. At this time, in order to ensure a sufficient amount of heat, it is also preferable to simultaneously perform radiant heating with an infrared heater in addition to heating with a suction heater.
The reinforcing portion 54 may be formed at the same time as the underlay 50 or after the general portion 52 is formed.

  Further, the end portion with the underlay reinforcement portion is shaped to warp upward from the normal laying position, and the rising portion near the end portion of the floor carpet 10 is formed from above with the upper support member 70 as shown in FIG. You may make it hold down. The end portion of the underlay 50 may be thinly formed so that the end portion 11 of the floor carpet is inserted behind the upper support member 70 so that the end portion 11 of the floor carpet cannot be seen. Thereby, the external appearance of a vehicle interior improves. Further, since there is no gap between the surface of the floor carpet 10 and the lower edge of the upper support member 70, the appearance of the passenger compartment can be maintained even when the underlay end portion, which is difficult to obtain accuracy, is floated. For the upper support member 70, an interior material that is installed on the side wall of the vehicle compartment, such as a pillar garnish, can be used.

The compression part 55 formed in the underlay 50 is increased in density and rigidity by press molding of the fiber structure 40. Further, the convex ribs 56 provided between the compression portions 55 bring about a shape-like bridging effect and increase the rigidity of the reinforcing portion 54. The reinforcing portion 54 formed in the underlay 50 is provided with a convex rib 56 between the compression portions 55 by press molding of the fiber structure 40, thereby increasing the rigidity of the general portion 52. As a result, the strength of the required portion is improved without increasing the weight of the underlay, and it is not necessary to change the composition of a separate support material or underlay. When the reinforcing portion 54 is provided at the end portion of the underlay 50, the convex rib 56 provides a bridging effect between the general portion 52 and the end portion of the underlay 50, and the floor rib end portion 11 is formed by the protruding rib 56 stretching. Becomes difficult to fall.
Further, when the web M1 in the convex rib 56 is bent in the stacking direction D1, the shape recoverability when compressed in the thickness direction D3 is increased, and thus the followability to the vehicle body panel 80 can be improved.

(3) Modification:
The present invention can be modified in various ways.
For example, the floor carpet may be provided with another layer such as a sound insulating layer such as an aperture resin layer, a sound absorbing layer, and a non-breathable resin layer between the design layer and the buffer material layer. In addition, felt or the like may be post-applied to the surface of the floor carpet having a cushioning material layer that serves as a cushioning material for vehicles. The felt may be a fiber structure in which constituent fibers are oriented in the thickness direction, a flat felt, or a molded felt.

The design layer and the cushioning material layer may be bonded to each other after being separately press-molded so as not to be separated. Alternatively, after forming a cushioning material for a vehicle by press-molding only the fiber structure, the cushioning material and the design material may be overlapped and press-molded together. Furthermore, after only the design material is press-molded to form only the design layer, the design layer and the fiber structure may be overlapped and press-molded together.
On the other hand, the vehicle cushioning material described above may be provided in the vehicle interior material so that it can be separated from the design layer or the like without being bonded to the design layer or the like.
The reinforcing part is located not only in the vicinity of the end of the vehicle interior material, but also on the inner side of the surrounding rising part in the vehicle interior material, such as a rising part disposed opposite to the tunnel part of the vehicle body panel and the foot part of the passenger. You may provide in a position.

(4) Example:
EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, this invention is not limited by the following examples.

[Adjusting the floor carpet before press molding]
As the carpet body, a needle punched carpet (Diloanipan, basis weight 250 g / m ² ) and thermoplastic backing resin (mass back, specific gravity 1.5, basis weight 2000 g / m ² ) was used.

Encapsulating 70% by weight of regular polyester fiber (average fiber diameter: 14dtex (decitex), average fiber length: 64mm) with a melting point of 250-260 ° C as the main fiber, and a low-melting point resin in which the polyester is modified around the regular polyester fiber The core-sheath structure fibers (average fiber diameter 2 dtex, average fiber length 51 mm, low melting point resin ratio 30% by weight) mixed with 30% by weight of fiber are aligned by carding, and the unit area weight is 40 g / m. ^2. A web with a thickness of 5 mm was formed. This web was repeatedly folded in the front and back directions to form a fiber structure having a thickness of 25 mm and a folding number of 100 times / 1000 mm per unit length. The carpet body was superposed on one surface of the fiber structure, and both were passed through a hot air oven having an atmospheric temperature of 210 ° C. to integrate them to form an original sample. At this time, the thickness of the fiber structure was reduced to 23 mm.
In each of the following examples, the original sample was cut into a rectangle having a length of 150 mm and a width of 50 mm, and heated and compressed to a target shape to form a press-molded sample.

[Example 1]
Cutting the original sample of 150 mm × 50 mm with the longitudinal direction facing the width direction of the web, and forming a convex rib along the longitudinal direction around the center of the short direction perpendicular to the longitudinal direction of the original sample, A press-molded sample having a convex rib having a width W1 = 10 to 25 mm at the base portion and a compression portion having a thickness T2 = 5 mm in the remaining portion was produced by heat compression. The longitudinal direction of the convex ribs of the obtained press-molded sample is directed to the web width direction as shown in FIG.

[Example 2]
Cutting the original sample of 150 mm × 50 mm facing the longitudinal direction in the web lamination direction, and forming a convex rib along the longitudinal direction around the center of the short direction perpendicular to the longitudinal direction of the original sample, A press-molded sample having a convex rib having a width W1 = 10 to 20 mm at the base portion and a compression portion having a thickness T2 = 5 mm in the remaining portion was produced by heating and compressing. As shown in FIG. 7B, the longitudinal direction of the convex ribs of the obtained press-molded sample faces the web lamination direction.

[Comparative Example 1]
A 150 mm × 50 mm original sample was cut in the longitudinal direction in the width direction of the web, and the entire surface of the fiber structure was heated and compressed to a thickness of 5 mm to prepare a press-molded sample.

[Comparative Example 2]
A 150 mm × 50 mm original sample was cut in the longitudinal direction in the web lamination direction, and the entire surface of the fiber structure was heated and compressed to a thickness of 5 mm to prepare a press-molded sample.

[Rigidity evaluation method]
14 (a) and 14 (b) are diagrams for illustrating a method for evaluating the rigidity of a press-molded sample, and FIG. 14 (a) is a diagram showing the press-molded sample from the outside in the short direction. (B) is the figure shown from the longitudinal direction outer side of the press molding sample. The bending test was performed at a pulling speed of 20 mm / min and a fulcrum distance of 50 mm.
Supporters SU1 and SU1 provided at positions of 50 mm from both ends in the longitudinal direction of the press-molded sample were formed so as to straddle the convex ribs so as not to directly press the convex ribs. About each press-molded sample, it supported by support tool SU1 and SU1, the center position between fulcrum was pressed with the presser P1 at the speed of 20 mm / min, the load which generate | occur | produced was measured, and the bending elastic gradient was obtained.

[Evaluation results]
The measurement result of the bending elastic gradient obtained by the above three-point bending test is shown in FIG. Here, the horizontal axis is the width W1 (mm) of the base portion of the convex rib, the vertical axis is the bending elastic gradient (N / mm), “A” is the result of Example 1 and Comparative Example 1, and “B” is the Example. 2 and the results of Comparative Example 2 are shown.

The bending elastic gradient of Example 1 was larger than the bending elastic gradient 5.0 of Comparative Example 1. The bending elastic gradient of Example 2 was larger than the bending elastic gradient 5.0 of Comparative Example 2.
From the above, it has been confirmed that providing a convex rib on the vehicle cushioning material increases the rigidity of the general part and improves the strength of the required part without increasing the weight of the cushioning material.

  In addition, the bending elastic gradient of Example 1 in which the longitudinal direction of the convex rib was oriented in the web width direction was larger than the bending elastic gradient of Example 2 in which the longitudinal direction of the convex rib was oriented in the web laminating direction as a whole. . Therefore, it has been confirmed that the effect of improving the strength of the required portion is greater when the longitudinal direction of the convex rib is oriented in the web width direction than when the longitudinal direction of the convex rib is oriented in the web lamination direction.

(5) Summary:
The fiber structure is not limited to a structure in which the fibers are oriented in the thickness direction and the web is repeatedly folded and laminated in the thickness direction. For example, it is possible to form a fiber structure in which fibers are oriented in the thickness direction by cutting the web into strips along the width direction and laminating the strip webs so that the fibers are oriented in the thickness direction. it can.
Of course, the above-described basic functions and effects can be obtained even with a vehicle cushioning material and a floor carpet that do not have the constituent requirements according to the dependent claims but only the constituent requirements according to the independent claims.

As described above, according to the present invention, useful vehicle cushioning materials, floor carpets, and the like can be provided according to various aspects.
In addition, it is also possible to implement the present invention by mutually replacing the configurations disclosed in the above-described embodiments and modifications, and changing the combination. It is also possible to carry out the present invention by substituting each component disclosed in the above or changing the combination. Therefore, the present invention is not limited to the above-described embodiments and modifications, and includes configurations in which the configurations disclosed in the publicly known technology and the above-described embodiments and modifications are mutually replaced or combinations thereof are changed. It is.

10 ... Floor carpet (vehicle interior material), 11 ... End,
20 ... carpet body (design material), 30 ... carpet layer (design layer),
40, 41 ... fiber structure, 40a ... front surface, 40b ... back surface,
45 ... main fiber, 46 ... adhesive fiber (binder), 47 ... folded portion,
50 ... Underlay (vehicle cushioning material), 50a ... Design layer side surface, 50b ... Panel side surface,
52 ... General part, 54 ... Reinforcement part, 55 ... Compression part,
56 ... convex rib, 56a ... top, 56b ... root,
70 ... Upper support material, 80 ... Body panel,
200 ... press molding machine,
D1 ... stacking direction, D2 ... width direction, D3 ... thickness direction,
D11 ... the extrusion direction of the fiber structure (one direction of the lamination direction),
D12 ... direction opposite to the extrusion direction (the other direction of the lamination direction),
M1, web, M2, folds, M3, bent portion, M4, first bent portion, M5, second bent portion,
SP1 ... Car compartment.

Claims (2)

In the manufacturing method of the cushioning material for vehicles provided on the vehicle body panel side of the floor carpet,
By performing press molding that compresses in the thickness direction on the fiber structure in which the webs are repeatedly laminated and the fibers are oriented in the thickness direction, a convex rib is provided between the general portion and the compression portion, and the web Including a step of forming a reinforcing portion that is bent in the web lamination direction and has increased rigidity with respect to the general portion,
In this step, the longitudinal direction of the convex rib along the floor carpet is arranged in the width direction of the web, so that the longitudinal direction of the convex rib along the floor carpet is directed in the web laminating direction. Compared with the case where it arranges, the angle | corner of the standup | rising part of the root part with respect to the said compression part is sharpened, The manufacturing method of the shock absorbing material for vehicles characterized by the above-mentioned. In the manufacturing method of the cushioning material for vehicles provided on the vehicle body panel side of the floor carpet,
By performing press molding that compresses in the thickness direction on the fiber structure in which the webs are repeatedly laminated and the fibers are oriented in the thickness direction, a convex rib is provided between the general portion and the compression portion, and the web Including a step of forming a reinforcing portion that is bent in the web lamination direction and has increased rigidity with respect to the general portion,
In the step, the longitudinal direction of the convex rib along the floor carpet is arranged in the web laminating direction so that the longitudinal direction of the convex rib along the floor carpet is oriented in the width direction of the web. Compared with the case where it arranges, the corner | angular part of the standup | rising part of the root part with respect to the said compression part is rounded, The manufacturing method of the shock absorbing material for vehicles characterized by the above-mentioned.

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