JPH02197436A - Floor carpet for automobile and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve sound insulation property and shape holding property of a carpet main body by arranging a second sound insullation layer on the footing part of the back of the carpet main body, and arranging urethane foam layer on the back of the second sound insulation layer. CONSTITUTION:A first sound insulation layer 3 of thermoplastic resin compounded with inorganic filler, is arranged on the back of foundation 2 of a carpet main body. In this case, a second sound insulation layer 4 of thermoplastic resin compounded with inorganic filler, similar to the former, is arranged on the footing part of the back of the carpet main body. Further, on the other face of the second sound insulation layer 4, an urethane foam layer 5 is arranged. Further, cushioning materials 6 such as felt, thick nonwoven fabric, or urethane foam chip sheet are arranged on the required part on the back of the carpet main body except the second sound insulation layer 4. Thus, sound insulation property or shape holding property of the carpet main body can be improved.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to an automobile floor carpet with improved sound insulation and appearance, and a manufacturing method.

<Conventional technology> Conventional sound-insulating carpets have been produced by molding mass-pack carpets that have a sound-insulating layer made of thermoplastic resin and inorganic filler on the back of the carpet greige, and then welding or gluing felt, etc. as a cushioning material to the back of the carpet. Molded floor carpet for automobiles having a sound insulating sheet made of one or more of rubber, asphalt, and thermoplastic resin and filler on the back side, and a cushion layer on the back side (equity 62-13907) It has been known.

As a thermoplastic resin, ethylene/vinyl acetate (Higashi 55
-113533) Ethylene/ethyl acrylate, polyolefin synthetic rubber compound (Jitsuma 56-132981)
Ethylene/unsaturated acrylic acid ester (time open 57-59
．． 941.59942) is known.

Regarding dispersing materials and methods for inorganic fillers, one method is to use a masterbatch made by kneading the inorganic filler with a low melting point resin such as polyethylene wax or atactic polypropylene that is compatible with the main component resin. A known method is to use lubricating oil for dispersion. (Problems to be solved by Jikai 57-59941.59942) The above-mentioned conventional molded floor carpet consisting of carpet - sound insulation layer - fiber felt or foamed urethane chip sheet has the following problems. There is.

(,) In order to improve the sound insulation properties of vehicles that generate loud noise such as diesel vehicles, there is a method of increasing the areal density of the sound insulation sheet, but this increases the weight of the carpet, making it extremely difficult to install the carpet, and the weight of the vehicle increases. There are problems such as increased fuel consumption and decreased fuel efficiency.

(b) Since the cushion layer on the back side is made of fiber felt and is flat, it does not fit well with uneven floor surfaces, and the shape of the carpet changes due to heat and external force during use, resulting in an unsightly appearance. In addition, deterioration of sound insulation properties due to the generation of gaps due to carpet deformation is a problem.

<Means for Solving the Problems> As a result of studies aimed at solving the above-mentioned problems, the present invention has been arrived at. That is, the present invention is a molded floor carpet consisting of a carpet having a sound insulating layer made of a thermoplastic resin and an inorganic filler mixed on the back side of the carpet greige. A second sound insulating layer is formed, the outer surface of the second sound insulating layer has a urethane foam layer, and felt, bulky non-woven fabric, or urethane foam is applied to the required places on the back surface of the carpet other than the second sound insulating layer. The problem could be solved by including a cushioning material such as a chip sheet. It is preferable that the non-welded surface of the urethane foam layer has a shape that fits into the unevenness of the automobile floor surface.The carpet used here is not limited, and commonly used tufted carpets, needle carpets, etc. can be used. Ru. The techniques described above are similarly used for the sound insulation layer.

The feature of the present invention is that the outer surface of the cushion layer is formed by injecting and foaming urethane into the back surface and has a shape that fits into the irregularities of the floor surface. The sound insulating layer of the sound insulating carpet is welded or bonded to the sound insulating layer.

Since the second sound insulating layer is used as a flat plate, it can be made of not only the first sound insulating layer but also other non-formable rubbers. The urethane injection agent uses a polyol such as a polyether polyol or a polyester polyol, a polyisocyanate such as toluene diisocyanate (TDI), diphenylmethane diisocyanate and its polynuclear product (MDI), and water as a blowing agent. Furthermore, a fluorocarbon such as fluorocarbon 11 can be used in combination as a foaming aid.

A catalyst may be used to accelerate or balance the reaction, and a foam stabilizer, a pigment, an inorganic filler, a filler such as glass fiber, etc. can be used to stabilize the generated foam.

Next, the manufacturing method will be explained. To perform urethane injection and foaming, a second sound-insulating sheet is first inserted into the injection mold coated with a mold release agent, and the reaction mixture is discharged into the mold from the stirring head of the foaming machine, creating a mold that fits into the large irregularities of the car floor. The mold is closed with a top lid with air vent holes, and foaming is performed.

Both a hot cure method and a cold cure method can be used for mold foaming. When hot curing, pass through a heating furnace at a higher temperature, approximately 180-250G.
-The cold cure method uses 7O-100 (?:) for 3-7 minutes, but in this case highly reactive raw materials are used.After foaming is complete, the mold is removed. Then, set it in a predetermined position in a mold with the urethane layer facing the mold surface, and set cushioning materials such as fiber felt and urethane chip sheets in other required places, and cut it into a certain length with a sound insulation layer. After heating and melting the sound insulation layer of the carpet in a heat furnace, the molten resin surface is turned to the surface on which the second sound insulation layer, etc. is set, and the outer periphery of the carpet is gripped at multiple points with a gripping tool, and cold press molded between it and the other mold. When this process is carried out, the second sound insulating layer and other cushioning materials are welded to the predetermined positions of the molded carpet at the same time as the molding.In some cases, the second sound insulating sheet may be preheated during this molding to prevent welding. Also, if welding is difficult, it is effective to apply quick-drying hot melt in advance.

Here, the urethane chip sheet is made by crushing the waste of a urethane foam product, hardening it with an adhesive, and then slicing it into a predetermined thickness.

(Function) A second sound insulation layer is laminated on the footwell of a molded floor carpet with a sound insulation layer laminated on the entire back side of the carpet, a urethane foam layer is placed on the opposite side, and fiber felt and urethane chip sheet are used on other necessary areas. It is preferable that the outer surface of the urethane foam layer is made by injection foaming so as to fit into the uneven shape of the floor because of its good fit.

A urethane-injected foam layer is formed on the back side of the second sound insulating layer, which provides good cushioning and prevents sagging, allowing the carpet to maintain its shape over time. Furthermore, if the urethane outer surface is formed to fit into the unevenness of the floor, the fit will be improved in some areas. By not using urethane in parts other than the second sound insulating layer and using other cushioning materials, there is no need to use expensive urethane especially in parts where large loads are not applied, and as a result, cost increases are suppressed. Limiting the sound insulating layer to only the footwell area is a problem that would be solved by using a double sound insulating layer on the entire surface> Since there is a problem as described in (a), it is not an effective area in terms of the intended quality In other words, only the foot storage part is removed.

The steps of the manufacturing method are as follows: First, a carpet is prepared by laminating a sound insulating layer on the back side of a carpet greige machine by melt-coating or the like. Separately, a second sound insulating sheet is made by melt extrusion or the like and cut into a predetermined shape. 6 Next, a part is prepared by laminating a foam of a predetermined shape on one side of the second sound insulating layer using a urethane injection foaming method.

The second sound insulating layer with foam layer and other cushioning materials are set in the predetermined positions of the lower mold, and the carpet is cut to a predetermined length.The back resin is heated and melted in a hot furnace, and immediately the resin side is turned toward the lower mold and placed between the upper and lower molds. When pressed, the molding, the second sound insulating layer and other cushioning materials are welded together. After being removed from the mold, it is processed to become automobile floor carpet.

<Example-1> 1/8G of 1600de nylon textured yarn pile on 120g/rrf polyester spunbond nonwoven fabric base fabric,
A tufted carpet gray machine was prepared by tufting at 37 st/ioam and a pile length of 10 mm. On the back of this thing, 25 parts of ethylene vinyl acetate (denoted as EVA) containing 28% vinyl acetate (denoted as VA) and 75 parts of Calpet A (calcium carbonate masterbatch made by Nitto Konka Co., Ltd.)
parts by weight and 1 part of color master patch were blended, and a 2 kg/- molten sheet was extruded using an extruder equipped with a T die and pressed between cooling rolls to obtain a carpet with a sound insulating layer.

On the other hand, only a sound insulating sheet was manufactured using the same method, cut into a predetermined shape, and inserted into a silicone-coated urethane injection foaming mold.Then, 60 parts by weight of polyether polyester having 3 OH groups (molecular weight 5100), diphenylmethane diisocyanate and its polynuclear 30 parts by weight of MDI, 3 parts of water, 1 part of triethylamine as a catalyst, and 0.5 parts of silicone oil as a foam stabilizer were stirred with a spray nozzle head and poured into a mold with a mold temperature of 60°C, so that the lid shape was on the floor. The mold was closed with a lid having an air vent hole that fit into the mold, and foaming was performed in an 85° C. curing oven for 6 minutes to remove the mold. Cycle time was 8 minutes.

Next, the surface of the second sound insulating layer is placed on the lower part of the mold at a predetermined position.
The urethane foam was preheated to °C and set in a predetermined position facing the floor, and fiber felt was set in other predetermined areas.

After cutting the carpet with a sound insulation layer into one piece, the sound insulation layer is heated in a heating furnace by far infrared rays to melt it, and the molten resin surface is facing the bottom mold surface, and the upper and lower molds are gripped at 12 places around the mold with a gripping tool. The second sound insulating layer and fiber felt were welded simultaneously with cold press molding. After that, we specialized in cutting the outer periphery, punching holes, and installing jigs to create the product automobile floor carpet.

When the resulting carpet was installed in a car and subjected to a thermal cycle test, it was found that there was little change in shape, the carpet maintained its aesthetic appearance, and the car was quieter.

Here, the thermal cycle test is 80"C 4 hours then room temperature (2
3''C) This is a test in which 4 cycles are performed, each cycle consisting of 1 hour at -40°C, 4 hours at room temperature, and 1 hour at room temperature to observe and measure changes in appearance and shape.

<Example-2> Cotton consisting of 30 parts of 6de J7i-dyed polyester cotton and 70 parts of 12de spun-dyed polyester cotton was defibrated and made into fleece through a card machine, and the fleece was laminated with a wrapping homer to form a web in a needle room 120 times/rn.
After punching, a nonwoven fabric of 370 g/m was obtained by punching with another patterned needle to form an enemy-like nap on the surface.

80% styrene/butadiene latex from the back side.
g/% floss coating and drying to obtain gray fabric. On the back of this is VA28% (7) EVA30 parts by weight, Mirast?
A sound insulating carpet consisting of 15 parts by weight of -8030 (olefin elastomer made by Mitsui Petrochemicals) and 55 parts by weight of Calpet A was melt-coated at 2 kg/rjr using an extruder with a T-die to obtain a sound insulating carpet.0 order VA% 12 EV of
2K consisting of 30 parts by weight of A and 70 parts by weight of Calvet A.
A second sound insulating sheet of g/m was produced using an extruder with a T die and cut into a predetermined shape.

The second sound insulating sheet was inserted into a urethane injection foaming mold onto which silicone oil was sprayed as a mold release agent, and 35 parts by weight of a polyol with a molecular weight of 4200 having 3 hydroxyl groups, 55 parts by weight of tolylene diisocyanate, and 5 parts by weight of water were added to the foam mold.
Using 3 parts of 1 and 1 part of catalyst as raw materials, pass through a stirring head to 4
The mixture was poured into a mold of No. 00, the upper lid having an air vent hole manufactured in a shape that fit the shape of the floor surface was closed, and the mixture was moved into a heat oven at 200°C for foaming and curing.
After processing for a minute, it was molded. The temperature during demolding was 95°C and the cycle time was 25 minutes.

Reference: The product was commercialized in the same manner as in Example 1 and subjected to a thermal cycle test. As a result, there was almost no change in the external shape, the aesthetic appearance was maintained, and the noise inside the car was improved.

<Effects of the Invention> By forming a second sound insulating layer on the back surface of the carpet in the footwell of the molded carpet and a urethane foam layer on its outer surface, the footwell remains flat for a long period of time and does not sag due to surface compression. I was able to maintain the shape. In addition, the sound insulation properties were improved, the noise inside the car was reduced, and the shape retention of the molded carpet was improved, and furthermore, a product with long-lasting quality was obtained.

[Brief explanation of the drawing]

FIG. 1 is a plan view of the back side of the product of the present invention, and FIG. 2 is a cross-sectional view taken along the X-X line of FIG. 1. In the figure, 1 is a bail, 2 is a base fabric, 3 is a first sound insulation layer, 4 is a second sound insulation layer, 5 is a urethane foam layer, and 6 is a fiber felt layer. Engraving of drawings (no changes in content) Drawings Figure 1 Figure 2

Claims (4)

[Claims] (1) A second sound insulating layer made of a thermoplastic resin and an inorganic filler is formed on the back of the footrest part of the carpet, which has a sound insulating layer made of a thermoplastic resin and an inorganic filler on the back side of the carpet gray fabric, and the second sound insulating layer is made of a thermoplastic resin and an inorganic filler. An automobile floor carpet that has a urethane foam layer on the other side, and has a cushioning material such as felt, bulky nonwoven fabric, or urethane foam chip sheet on the necessary parts of the back side of the carpet other than the second sound insulation layer. (2) An automobile floor mat according to claim 1, wherein the outer surface of the urethane foam layer has a shape that fits into the unevenness of the floor surface. (3) Claim 1, wherein the thermoplastic resin is mainly composed of one or more of ethylene/vinyl acetate, ethylene/ethyl acrylate, olefin elastomer, and butadiene elastomer. car floor carpet (4) (a) A carpet is made by melt-coating a mixture of thermoplastic resin and inorganic filler on the back side of the carpet gray fabric (b) A resin consisting of thermoplastic resin and inorganic filler, or thermoplastic resin and rubber or/and asphalt. After mixing the inorganic filler with the inorganic filler, the sound insulation sheet of (c) and (b) is cut into a certain shape, then inserted into a urethane injection mold, and the urethane foam stock solution is injected onto it.
The top cover, which is shaped to fit into the unevenness of the car floor surface, is closed, fired, passed through a heating furnace, cured, and removed from the mold, and the urethane foam layer is fused to the sound insulation sheet.Manufactured in (d) and (c). Place the sound insulating sheet with urethane foam in the mold with the urethane side facing, and set other cushioning materials in other necessary areas. (E) After cutting the carpet from (B) to a predetermined length, heat and melt the sound insulating layer surface, then grip key points on the outer periphery with that surface facing the second sound insulating layer surface set on the mold, and place it between the other molds. The second sound insulating layer and other cushioning materials are welded at the same time as cold press molding is performed. A method for manufacturing an automobile floor carpet, characterized by passing through the above steps (a), (b), (c), (d), and (e) and further a step of attaching a circumferential cutting stopper.