JP7253842B1 - Vehicle floor carpet and method for manufacturing vehicle floor carpet - Google Patents

Abstract

An object of the present invention is to provide an in-vehicle floor carpet and a method of manufacturing the same, which can promote weight reduction of a vehicle body. The vehicle floor carpet comprises a carpet main body formed by fixing a plurality of pile yarns to a base fabric, and a mesh sheet, which is arranged on the back side of the carpet main body with respect to the carpet main body. and a bonding portion for bonding the carpet body and the backing to each other. The bonding includes an intermediate portion interposed between the carpet body and the backing, and a thickness a protruding portion extending in the direction opposite to the main body of the carpet in the direction of the backing material, penetrating through the gaps in the mesh of the backing material, and protruding from the gaps in the mesh in the direction opposite to the main body of the carpet in the backing material; have. [Selection drawing] Fig. 3

Description

The present invention relates to a vehicle floor carpet and a method of manufacturing the vehicle floor carpet.

A vehicle floor carpet is constructed by joining a backing material to a carpet main body in which pile yarn is implanted in a base fabric.

Backing materials for vehicle floor carpets are generally made of SBS (styrene-butadiene-styrene block copolymer) or felt material. The backing material made of SBS is directly bonded to the carpet main body after being heat-melted, and the backing material made of felt is made by interposing polyethylene as an adhesive and then heating the polyethylene. Join by melting. The SBS or felt material forms a non-slip when the vehicle floor carpet is laid on the floor panel in the passenger compartment.

Here, the carpet body is formed by using latex as an adhesive and fixing a large number of pile threads to the base fabric with latex. After that, an SBS type backing material is directly joined to the carpet main body or a felt material type backing material is joined through polyethylene to complete the vehicle floor carpet.

Patent Document 1 discloses a three-layer structure consisting of a carpet cloth portion, a back side cloth portion, and an elastic portion disposed between the carpet cloth portion and the back side cloth portion for adhering these cloth portions to each other. An automotive floor carpet is disclosed.

JP 2014-100966 A

In recent years, with the reduction of carbon dioxide emissions as a background, electric vehicles are becoming more and more popular. However, there is a demand for further weight reduction of vehicle bodies because of the heavy weight of on-vehicle batteries.

Conventional vehicle floor carpets have relatively heavy backing materials, making it difficult to meet such demands. For example, the weight of the SBS type backing material is 1.6 kg/m ² and the weight of the felt material type backing material is 550 g/m ² including the adhesive polyethylene.

In view of such circumstances, the present invention provides an in-vehicle floor carpet that can be formed more lightweight and that can promote weight reduction of the vehicle body, and a method for manufacturing such an in-vehicle floor carpet. for the purpose.

The invention according to claim 1 is a floor carpet for vehicle use, comprising: a carpet main body formed by fixing a plurality of pile yarns to a base fabric; and a bonding portion for bonding the carpet main body and the backing material to each other, the bonding portion comprising an intermediate portion interposed between the carpet main body and the backing material; Extending from the intermediate portion in the direction of the thickness of the backing material in the direction opposite to the carpet main body, penetrating through the gaps in the mesh of the backing material and extending from the gaps in the mesh in the direction of the backing material in the direction opposite to the carpet main body. and a protruding protrusion.

The invention according to claim 2 is characterized in that the backing member is made of glass fiber, polyethylene, polypropylene, nylon, polyester, or polycarbonate.

The invention according to claim 3 is characterized in that the adhesive portion is made of a thermoplastic resin.

The invention according to claim 4 is characterized in that the thermoplastic resin is polyethylene.

According to a fifth aspect of the present invention, the protrusions of the bonding portion have a constricted shape in which each portion protruding from each of the gaps in the mesh tapers.

The invention according to claim 6 is characterized by further comprising a grommet engagement portion formed by penetrating the carpet body portion and the backing material portion over the front and back of the vehicle floor carpet.

According to a seventh aspect of the invention, there is provided a method for manufacturing an in-vehicle floor carpet, comprising a surface material formed by fixing a plurality of pile yarns to a base fabric, a back surface material formed in a mesh sheet, and a surface material. and an adhesive made of a thermoplastic resin for adhering the backing material to each other are prepared. By crimping in a molten state, the adhesive protrudes in the direction opposite to the surface material of the back surface material through the gaps in the mesh of the back surface material, and after the back surface material is crimped to the surface material, the adhesive is cured. and

According to the first aspect of the invention, the carpet main body and the mesh sheet-like backing material are superimposed via the adhesive portion and adhered to each other. In addition, since it is not necessary to use a felt material that is adhesively fixed with polyethylene as a backing material, the weight of the backing material and the adhesive part can be reduced, and the weight of the entire vehicle floor carpet can be reduced. For example, it is possible to reduce the weight of the backing part and the adhesive part by about 30% compared to conventional car floor carpets using felt material.

Here, since the adhesive portion has an intermediate portion and a projecting portion, and the projecting portion projects in the direction of the backing material portion opposite to the main body portion of the carpet through the gaps in the mesh of the backing material portion, the projecting portion (specifically, , the portion protruding from the gaps in the mesh) functions as an anti-slip to prevent the vehicle floor carpet from slipping when the vehicle is running, that is, from moving in the front, back, left, and right directions with respect to the floor panel.

Furthermore, since the backing material is in the form of a mesh sheet, the backing material itself has elasticity in the planar direction. Even if a tensile force acts in the direction, the backing part is locally deformed in the surface direction and absorbs the tensile force, thereby avoiding the situation where the deformation extends to the whole or a wide range of the vehicle floor carpet. Is possible.
As a result, it is possible to effectively avoid a situation in which the entire vehicle floor carpet is deformed, and it is possible to maintain the quality of the vehicle floor carpet over time.

Furthermore, since the mesh sheet-like backing material is exposed on the back side of the in-vehicle floor carpet, it is possible to give the impression that the back side of the in-vehicle floor carpet has an intricate pattern. can be made good.

According to the second aspect of the invention, it is possible to provide a suitable backing material for promoting weight reduction of the vehicle floor carpet.

According to the third aspect of the invention, there is provided an adhesive portion that achieves both appropriate adhesiveness to the carpet main body and backing material and fluidity when passing through the mesh gaps of the backing material. Is possible.

According to the fourth aspect of the invention, it is possible to provide a more suitable backing material for achieving both adhesiveness and fluidity.

According to the fifth aspect of the invention, the protrusions of the adhesive portion (specifically, individual portions of the protrusions that protrude from the respective gaps in the mesh of the backing member) are narrowed at the tip. By having the tapered shape, it is possible to satisfactorily lock the protrusion to the surface of the floor panel and obtain an appropriate anti-slip effect on the floor panel.

According to the sixth aspect of the invention, the grommet provided on the floor panel can be engaged with the grommet engaging portion, thereby suppressing displacement of the vehicle floor carpet with respect to the floor panel.

According to the seventh aspect of the invention, the backing material formed in the form of a mesh sheet is adopted, and the surface material and the backing material are overlapped with each other via an adhesive made of a thermoplastic resin. , the weight of the backing material and adhesive can be reduced, and the weight of the entire vehicle floor carpet can be reduced.

Here, the adhesive in a heat-melted state is protruded in the direction opposite to the skin material of the back surface material through the gaps of the mesh of the back surface material, and then cured, so that the mesh of the adhesive after curing is The portion protruding from the gap functions as a non-slip, and it is possible to prevent the vehicle floor carpet from slipping while the vehicle is running.

In addition, the backing material itself is a mesh sheet, so that the backing material itself has elasticity in the plane direction. It is possible to absorb this tensile force and avoid the situation where the entire vehicle floor carpet is deformed.

Furthermore, after the adhesive has hardened, the mesh sheet-like backing material is exposed on the back side of the vehicle floor carpet, so that the back surface of the vehicle floor carpet gives the impression that the back surface of the vehicle floor carpet has a dense pattern. It is possible to improve the appearance quality of the vehicle floor carpet.

FIG. 1 is a schematic diagram schematically showing the appearance of an in-vehicle floor carpet according to one embodiment of the present invention. FIG. 2 is (a) a plan view, (b) a bottom view, and (c) a side view of the vehicle floor carpet according to the embodiment. FIG. 3 is a cross-sectional view showing the layered structure of the vehicle floor carpet according to the embodiment, and FIG. 3(b) shows the layered structure in an enlarged view. FIG. 4 is an explanatory view schematically showing the manufacturing process of the floor carpet for vehicle according to the same embodiment. FIG. 5 is an explanatory diagram showing a deformation state in a tensile test of the floor carpet for vehicle according to the same embodiment.

Embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a schematic diagram schematically showing the appearance of an in-vehicle floor carpet 101 according to one embodiment of the present invention.

FIG. 2 is a plan view of the vehicle-mounted floor carpet 101 according to the present embodiment as seen from (a) the carpet main body 1 side (that is, the surface 101s side of the carpet), and (b) the backing material 2 side (that is, the carpet surface). 101r side) and (c) a side view.

FIG. 1 shows the in-vehicle floor carpet 101 upside down, in other words, shows the front surface 101s of the in-vehicle floor carpet 101 downward and the back surface 101r upward in the paper. This is to show that the appearance of the backing material 2, which is a feature of the vehicle floor carpet 101 according to the present embodiment, that is, the shape of the backing material 2 is a mesh sheet.

FIG. 1 shows the in-vehicle floor carpet 101 cut into a rectangular shape, but the in-vehicle floor carpet 101 can be formed in an appropriate shape according to the actual floor shape of the driver's seat. As a result, it can be laid on the floor panel of the driver's seat and avoid interference with various operation pedals such as an accelerator pedal, a brake pedal, and a parking brake pedal.

The configuration of a vehicle floor carpet 101 according to the present embodiment will be described based on FIG. 1 while appropriately referring to FIG.

A vehicle floor carpet 101 according to this embodiment includes a carpet main body portion 1 , a backing material portion 2 and an adhesive portion 3 .

The carpet main body 1 is formed by fixing a large number of pile yarns 11 to a base fabric 12 using latex as an adhesive, and the pile yarns 11 form the surface 101s of the vehicle floor carpet 101 . In the present embodiment, the configuration of the carpet body 1 itself may be the same as that employed in conventionally known floor carpets or floor mats (for example, tufted carpets). A detailed description is omitted.

As shown in FIG. 2(b), the backing material 2 is in the form of a mesh sheet and is arranged on the rear surface 101r side of the vehicle floor carpet 101 with respect to the carpet main body 1. As shown in FIG. In this embodiment, the backing material 2 is made of polyester, and specifically, it is formed by knitting together a plurality of members made of polyester in the form of wires or threads in mutually intersecting directions, for example, in the vertical and horizontal directions. be done.

The material applied to the backing member 2 is not limited to polyester, and in addition to polyester, suitable materials such as glass fiber, polypropylene, nylon, polyethylene, and polycarbonate can be adopted.

The bonding portion 3 bonds the carpet main body portion 1 and the backing material portion 2 to each other, and is made of a thermoplastic resin in this embodiment. Polyethylene can be exemplified as a thermoplastic resin that can be applied to the bonding portion 3 according to this embodiment.

FIG. 3 is a cross-sectional view showing the layered structure of the vehicle floor carpet 101 according to this embodiment. 3(a) shows the configuration of the vehicle floor carpet 101 by a cross section taken along line xx in FIG. 2(b), and FIG. 3(b) is shown by a two-dot chain line in FIG. 2(a). The portion surrounded by the frame A is enlarged and shown.

With reference to FIG. 3, the vehicle floor carpet 101 according to the present embodiment, particularly the configuration of the adhesive portion 3, will be further described.

The bonding portion 3 has an intermediate portion 31 and a projecting portion 32 .

The intermediate portion 31 is a portion of the adhesive portion 3 interposed between the carpet body portion 1 and the backing portion 2 in the thickness direction Dth of the vehicle floor carpet 101 or the adhesive portion 3 itself. It extends in the planar direction Dpl of the carpet 101 and forms a sheet as a whole. In this embodiment, the joint strength for bonding the carpet body 1 and the backing material 2 is mainly exerted by the intermediate portion 31 .

The protruding portion 32 is formed integrally with the intermediate portion 31 from the same material (polyethylene in this embodiment), and extends from the intermediate portion 31 in the direction opposite to the carpet body portion of the backing material portion 2 in the thickness direction Dth. extend towards. Here, "the direction opposite to the carpet main body" refers to the direction facing the opposite side of the carpet main body 1 with respect to the backing material 2. In the example shown in FIG. 2 corresponds to the upward direction.

The protruding portion 32 penetrates the mesh gap g of the backing material portion 2 and slightly protrudes from the mesh gap g in the direction of the backing material portion 2 opposite to the main body of the carpet. In the present embodiment, the protruding portion 32 has a constricted shape in which each portion protruding from each of the gaps g of the mesh tapers toward the tip.

For the sake of explanation, FIG. 3(b) shows a case in which all the projections 32 have a clear constriction shape and protrude from the gap g of the mesh. The protruding portion 32 extending from the mesh to the extent that it penetrates the gap g of the mesh may be a part of the protruding portion 32 provided on the entire bonding portion 3 .

FIG. 4 is an explanatory view schematically showing the manufacturing process of the vehicle floor carpet 101 according to this embodiment.

In the following description, the same reference numerals as those shown in FIGS. 1 to 3 are given to the elements or materials constituting the corresponding portions of the vehicle floor carpet 101 previously described.

The manufacturing process of the in-vehicle floor carpet 101 is roughly divided into the following three processes.
(A) A first step of preparing the skin material 1, the back material 2 and the adhesive 3 (B) The skin material 1, the adhesive 3 and the back material 2 are laminated in this order to form a laminate, and the skin material (C) A third step of curing the adhesive 3 after the backing material 2 is pressure-bonded to the surface material 1.

In the present embodiment, the first step is to install the carpet material roll R1 around which the surface material 1 is wound and the backing material roll R2 around which the backing material 2 is wound, and to place the extruder 201 in an operable state. embodied. The surface material 1 forms a "carpet body" in the vehicle floor carpet 101, and the backing material 2 forms a "backing material".

As an extruder 201 applicable to the manufacturing process of the vehicle floor carpet 101 according to this embodiment, a T-die lamination extruder can be exemplified. The extruder 201 has, for example, a container (not shown) that receives an adhesive that is distributed in the form of granules or pellets, and the adhesive contained in the container is supplied to a built-in heater 202. Feed and heat to melt. Then, this adhesive is discharged in a hot melted state through a nozzle 203 at the tip. The adhesive 3 forms a "bonding portion" in the vehicle floor carpet 101, and is made of a thermoplastic resin, polyethylene in this embodiment.

In the second step, the skin material 1 supplied from the carpet material roll R1, the backing material 2 supplied from the backing material roll R2, and the adhesive 3 supplied from the extruder 201 are superposed on each other to form a laminate. , a pair of pressure rollers, i.e., a first pressure roller R31 arranged on the carpet material roll R1 side and in contact with the skin material 1, and a second pressure roller R32 arranged on the backing material roll R2 side and in contact with the backing material 2. , pressing the laminate from its front and back or from both upper and lower sides.

In this embodiment, an intermediate roller R4 is provided between the carpet material roll R1 and the first pressure roller R31, and the skin material 1 fed out from the carpet material roll R1 is turned by the intermediate roller R4 and then pressed against the first pressure roller R31. Supplied to R31.

Then, between the first and second pressure rollers R31 and R32, the backing material 2 is pressed against the skin material 1 via the adhesive 3 made of polyethylene in a heat-melted state. A part of it is pushed into the gap g of the mesh of the backing material 2, passes through the gap g of the mesh, and protrudes in the direction of the backing material 2 opposite to the main body of the carpet.

The third step is embodied as a step of cooling the laminate of the surface material 1, the backing material 2 and the adhesive 3 after the second step. As a result, the adhesive 3 is cured and the vehicle floor carpet 101 is completed.

Here, the magnitude of the force when pressing the laminate in the second step is such that the adhesive 3 in the molten state flows through the gaps g of the mesh of the backing material 2 due to its fluidity to the backing material 2 against the carpet. It should be to the extent that it can protrude in the direction of the main body. Further force is applied to the adhesive 3 that has reached the pressing surface of the pressure roller R32 in contact with the backing material 2 through the gap g of the mesh of the backing material 2, so that the adhesive 3 is moderately protruded from the gap g of the meshing. It is possible to form a protruding portion 32 having a tapered tip at the adhesive portion 3 after curing.

In this embodiment, the skin material 1, the adhesive 3, and the backing material 2 are laminated in this order to form a laminate, and the laminate is pressed from both sides by pressure rollers R31 and R32. By extruding the adhesive 3 in a molten state from the extruder 201 and laminating it together with the skin material 1 and the backing material 2, the backing material 2 can be pressed against the skin material 1 via the adhesive 3 in a molten state. It is possible. The procedure for forming the laminate is not limited to this. After laminating the adhesive 3, the skin material 1 may be laminated.

The in-vehicle floor carpet 101 according to this embodiment has the above configuration, and the effects obtained by this embodiment will be described below.

Firstly, the vehicle floor carpet 101 is composed of a carpet main body 1 and a mesh sheet-like backing material 2 which are superimposed via an adhesive 3 and joined together by the adhesive 3 made of polyethylene. By solidifying the adhesive 3 in an eluted state from the mesh sheet-like gaps g constituting the 2, a large number of small protrusions 32 can be formed. As a result, the weight of the backing material portion 2 and the adhesive portion 3 can be reduced, and the weight of the vehicle floor carpet 101 as a whole can be reduced.

For example, the weight of the backing material 2 is reduced, although the amount (weight) of the adhesive itself used to form the adhesive part 3 is not significantly different from that of a conventional floor carpet for vehicles using a felt material. By doing so, it is possible to reduce the weight of the backing material portion 2 and the adhesive portion 3 by about 30%.

As an example, the weight of the felt material/polyethylene type backing material is 550 g/m ² including the polyethylene adhesive (300 g/m ² for the felt material and 250 g/m ² for the adhesive), In this embodiment, the total weight of the backing material part 2 and the adhesive part 3 is 350 g/m ² (the backing material part 2 (polyester) is 100 g/m ² and the adhesive part 3 (polyethylene) is 250 g/m ² ).

Here, the adhesive portion 3 has an intermediate portion 31 and a protruding portion 32, and the protruding portion 32 protrudes in the direction opposite to the carpet body portion of the backing material portion 2 through the mesh gap g of the backing material portion 2. Therefore, the projecting portion 32 (specifically, the portion projecting from the mesh gap g) functions as an anti-slip to prevent the in-vehicle floor carpet 101 from slipping when the vehicle is running, that is, in the front, rear, left, and right directions with respect to the floor panel. Movement can be suppressed.

Further, since the backing member 2 is formed in a mesh sheet shape, the backing member 2 itself has elasticity in the planar direction (which coincides with the planar direction Dpl shown in FIG. 3(b)). On the other hand, when the vehicle is running, even if a tensile force acts in the front, rear, left, and right directions from the grommet attached to the floor panel, the backing member 2 is locally deformed and absorbs the tensile force, thereby preventing deformation. It is possible to avoid a situation in which the vehicle floor carpet 101 as a whole is lifted from the floor panel.

FIG. 5 is an explanatory diagram showing a deformation state in a tensile test of the vehicle floor carpet 101 according to this embodiment.

The vehicle-mounted floor carpet 101 includes a grommet locking portion 105 formed by penetrating the entire laminate, that is, the carpet body portion 1, the adhesive portion 3, and the backing portion 2 over the front and back of the vehicle-mounted floor carpet 101. . By providing the grommet engaging portion 105, when the vehicle floor carpet 101 is actually installed on the floor panel, the grommet attached to the floor panel is engaged with the grommet engaging portion 105, and the vehicle floor carpet 101 is installed. It is possible to suppress the displacement of the floor panel.

In the tensile test, a tensile tester 301 is prepared, hooks 106 instead of actual grommets are engaged with the grommet engaging portions 105, and a force applied to the grommet engaging portions 105 via the hooks 106 is measured by the tensile tester. 301 measures. FIG. 5 shows the direction of force applied to the grommet locking portion 105 by an arrow a.

According to the present embodiment, when a force is applied to the grommet engaging portion 105 via the hook 106 in the direction of the arrow a, the mesh sheet-like backing material portion 2 is locally deformed, resulting in this tension. It is possible to absorb the force and avoid the deformation affecting the whole or wide area of the car floor carpet.

Furthermore, since the mesh sheet-like backing material portion 2 is exposed on the back surface 101r side of the vehicle floor carpet 101, the rear surface 101r of the vehicle floor carpet 101 has a dense and well-ordered pattern. can be provided, and the appearance quality of the vehicle floor carpet 101 can be improved.

In addition, since the backing material 2 is made of polyester, it is possible to reduce the weight of the backing material 2 while ensuring the necessary strength of the backing material 2, which promotes weight reduction of the vehicle floor carpet 101. It is possible to provide a suitable backing member 2 for this purpose. Similar effects can be obtained with glass fiber, polypropylene, nylon, polyethylene or polycarbonate, in addition to polyester.

Furthermore, by forming the adhesive part 3 from a thermoplastic resin, it is possible to achieve a suitable adhesiveness to the carpet main body part 1 and the backing material part 2 and fluidity when passing through the mesh gap g of the backing material part 2. It is possible to achieve both. By employing polyethylene as the thermoplastic resin, it is possible to provide the backing material portion 2 more suitable for achieving both adhesiveness and fluidity.

In addition, the protruding portions 32 of the adhesive portion 3 (specifically, the individual portions of the protruding portions 32 that protrude from the gaps g of the mesh of the backing portion 2) have a tapered shape that narrows toward the end. Thus, it is possible to satisfactorily lock the protrusion 32 to the surface of the floor panel and obtain an appropriate anti-slip effect on the floor panel.

DESCRIPTION OF SYMBOLS 101... Vehicle-mounted floor carpet 101s... Surface of vehicle-mounted floor carpet 101r... Back surface of vehicle-mounted floor carpet 1... Carpet main part (skin material)
DESCRIPTION OF SYMBOLS 11... Pile thread 12... Base fabric 2... Back material part (back material)
3 ... Adhesion part (adhesive)
REFERENCE SIGNS LIST 31 Intermediate portion 32 Protruding portion g Gaps in mesh Dth Thickness direction Dpl Planar direction R1 Carpet material roll R2 Backing material roll R31 First pressure roller R32 Second pressure roller R4 Intermediate roller 105 Grommet locking portion 106 Hook 201 Extruder 202 Heater 203 Nozzle 301 Tensile tester 302 Weight

Claims (7)

a carpet main body formed by fixing a plurality of pile yarns to a base fabric;
a backing material having a mesh sheet shape and arranged on the back side of the carpet main body with respect to the carpet main body;
a bonding portion that bonds the carpet body portion and the backing portion to each other;
The adhesive portion is
an intermediate portion interposed between the carpet body portion and the backing portion;
extending from the intermediate portion toward the direction opposite to the carpet main body portion in the thickness direction, penetrating through the gaps of the mesh of the backing material portion, and passing through the gaps of the mesh of the backing portion. and a projecting portion projecting in a direction opposite to the carpet body portion. 2. The vehicle floor carpet according to claim 1, wherein said backing material is made of glass fiber, polyethylene, polypropylene, nylon, polyester or polycarbonate. 3. The vehicle floor carpet according to claim 1, wherein said adhesive portion is made of a thermoplastic resin. 4. The vehicle floor carpet according to claim 3, wherein said thermoplastic resin is polyethylene. 5. The in-vehicle vehicle according to any one of claims 1 to 4, wherein the projecting portion of the bonding portion has a constricted shape in which each portion projecting from each of the gaps in the mesh tapers toward a tip. floor carpet. 6. The vehicle according to any one of claims 1 to 5, further comprising a grommet engagement portion formed by penetrating the carpet body portion and the backing material portion over the front and back of the vehicle floor carpet. Vehicle floor carpet as described. A surface material formed by fixing a plurality of pile yarns to a base fabric, a back surface material formed in the form of a mesh sheet, and an adhesive made of a thermoplastic resin for adhering the surface material and the back surface material to each other. prepare the
The skin material, the adhesive, and the back material are superimposed in this order, and the back material is pressure-bonded to the skin material in a state in which the adhesive is heat-melted, so that the adhesive is Projecting the back surface material in the opposite direction to the skin material through the gaps in the mesh of the back surface material,
A method of manufacturing a vehicle floor carpet, wherein the adhesive is cured after the backing material is pressure-bonded to the surface material.

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