JPH04274938A - Floor carpet for automobile and manufacture thereof - Google Patents

Abstract

PURPOSE:To make a shock absorbing part of low density in a body with a general part by clamping the floor carpet, to which urethane foam of specified density corresponding to low density is stuck, until the cells are crushed, and restoring the thickness of the urethane foam, using a mold, after injecting an undiluted foaming urethane resin solution and foaming it. CONSTITUTION:Slab urethane foam is stuck to the required place of the vertical wall at the rear of the floor carpet material 1 subjected to division in advance, being cut into the thickness of a shock absorbing material 2 required finally and the size above the required part. The density of the slab urethane foam is above 0.01g/cm<3> and below 0.03g/cm<3>. This floor carpet material 1 is arranged in unclamped condition on a lower mold 4, with the rear up, and then it is clamped and foaming urethane resin is injected and foamed. The injection mold shall have the cavity 5 in the shape corresponding to the general part 2 of the shock absorbing material 2 in the clamped condition, and be in the shape that the cells of the urethane foam is compressed until crushed at this time.

Description

[Detailed description of the invention]

0001

[Field of Industrial Application] The present invention relates to a floor carpet laid on the floor panel of an automobile, and more specifically, a cushioning material mainly made of urethane foam is integrally formed on the back side of the floor carpet. The present invention relates to a floor carpet for automobiles.

0002

2. Description of the Related Art Conventionally, floor carpets have been laid on the floor panels of automobiles for various purposes such as decoration.

The most common structure of floor carpets in recent years will be described below along with the manufacturing process. In other words, a backing such as polyethylene or polyethylene-vinyl acetate copolymer is placed on the back side of a fiber layer made of fiber materials such as polyester or nylon organized by techniques such as tufting or needling to lock and shape the fibers. The carpet material formed by laminating the materials is heated from the backing material side to soften the backing material, shape and solidify the floor carpet, and after demolding, the carpet is made into a mold for injecting urethane resin. Relocate the carpet, inject foaming urethane stock solution onto the back side of the carpet,
It is foamed and integrally formed into a floor carpet as a cushioning material.

[0004] The urethane foam that is injected and foamed as a cushioning material for this type of carpet has a density of approximately 0.05.
g/cm3 or more and less than 0.20 g/cm3.

The factors that limit the density of urethane foam are that the upper limit is mainly due to weight restrictions, while the lower limit is due to its dent resistance.

[0006] Generally speaking, as the density of urethane foam decreases, its compression resistance tends to decrease. If a large load is applied locally to the surface of the carpet (by high heels, the tip of an umbrella, etc.), the cushioning material in this area will not be able to support the pressure and will undergo large elastic deformations as shown in Figure 4. This is because depressions may be formed in the surface, giving the person concerned an unpleasant tactile sensation.

However, in some cases, it may be necessary to partially set the density of the cushioning material to less than 0.05 g/cm3. In other words, one is to reduce weight on the vertical surface of a carpet that does not receive direct loads, and the other is to reduce the weight of the carpet on the vertical surface, and the other is when trying to reduce the weight of a carpet on a floor panel that has irregularities such as wire harnesses whose positions are not determined. When a floor carpet is laid on a floor, the density of the cushioning material in this area is lowered to make it softer and absorb the unevenness. On such elevations, cushioning material (injection type) is applied to accommodate the minute irregularities.
It is technically easier and less costly to make the cushioning material in this part sufficiently soft to absorb minute irregularities than to set the shape of the part.

However, if it is desired to continuously mold urethane of different hardness into one piece, the conventional method has been to use two or more injection heads corresponding to at least a low-density part and a high-density part, respectively. It was necessary to inject the corresponding foamable urethane resin. Such a method requires complicated equipment, and has the drawback that operation and maintenance are complicated.

[0009]

Problems to be Solved by the Invention The present invention has been made in view of the above-mentioned problems, and it is an object of the present invention to provide a cushioning material with partially different hardness, particularly with a lower density and lower hardness than the general portion. To provide a method for forming a floor carpet integrally with a floor carpet without requiring any special equipment.

0010

[Means for Solving the Problems] The means of the present invention for solving the problems is to place a floor carpet, which has been shaped in advance and has urethane foam of a corresponding density adhered to the low-density portion, on the lower mold of a urethane injection mold. The urethane foam is placed in the upper mold and clamped until the cells of the urethane foam are substantially collapsed.The urethane stock solution is injected into the cavity and foamed to form the general part.Then, the mold is opened and the thickness of the urethane foam adhered is adjusted. By restoring the thickness to the thickness before mold clamping and forming the low density part integrally with the general part.

[0011]

EXAMPLES Examples of the present invention will be described below with reference to the drawings, but unless otherwise stated, the scope of the invention is not limited thereto, and these are merely illustrative examples.

[0012] This type of automotive floor carpet is composed of a carpet material made of synthetic fibers such as polyester or polypropylene organized by techniques such as tufting or needling, and a thermoplastic resin such as polyethylene or polyethylene-vinyl acetate copolymer. It is made by lining with a backing material, which is the main material, and is laid after being shaped to match the shape of the floor panel.

[0013] In this carpet molding method, the backing material is softened by heating the carpet with a far-infrared heater or the like, and the backing material is transferred into a mold, and the mold is clamped and shaped.

[0014] Low-density, flexible so-called slab urethane foam is applied to the required places on the back side of the floor carpet material, which has been shaped in advance through the above-mentioned process, and is applied to the standing walls of the floor carpet to provide the cushioning material that will ultimately be required. Cut it to a thickness that is at least as large as the required area and stick it on. The density of the slab urethane foam is 0.01g
/cm3 or more and less than 0.03g/cm3. The attachment method can be carried out by using an adhesive tape or the like on the surface of the slab urethane foam.

[0015] When this floor carpet material is opened into a urethane resin injection mold having an upper mold and a lower mold,
Place the mold with the back side up on the lower mold and tighten the mold. The shape of the injection mold is such that it has a cavity in a shape corresponding to the general portion of the cushioning material, at least in the clamped state, and is compressed until the cells of the slab urethane foam are substantially collapsed at this time.

A foamable urethane resin is injected into the cavity of the injection mold and foamed. The injection liquid consists of a foaming polyurethane stock solution, polyols (liquid A), and isocyanates (liquid B).
A filler and the like are mixed in the A liquid or the B liquid as necessary, and the liquid is stirred and mixed in the injection head and injected to form the general part of the buffer material. The injection pressure is often relatively low. The density of the injected urethane foam is 0.05 g/cm3 or more and less than 0.20 g/cm3.

[0017] In this injection process, the shape of the upper mold is set so that when the upper mold is closed, the cells of the slab urethane foam that have been previously pasted on the required parts of the carpet are collapsed. During the foaming process in which the urethane stock solution is injected into the injection mold, the injection solution does not penetrate into the interior of the slab urethane foam, which has been compressed to a thickness that substantially collapses the cells, except for the surface.

[0018] Therefore, when the injection process is completed and the foaming and hardening of the injected urethane stock solution is almost completed, the mold is opened and the product is removed from the mold, and the pressure applied to the slab urethane foam is removed and the essentially The flexible slab urethane foam immediately recovers its original thickness, and naturally communicates with the general area at the interface of the injected urethane, forming a low-density area integrally from this general area.

[0019]

As described above, in the automobile floor carpet of the present invention, the partial low-density part of the cushioning material mainly made of urethane resin is formed integrally with the general part, and moreover, this is made by special equipment. This is possible by changing the shape of the injection mold.

[Brief explanation of the drawing]

[Fig. 1] Example of the floor carpet of the present invention, perspective view of the back side

[Figure 2] Cross-sectional view taken along line A-A in Figure 1

[Figure 3] Conceptual diagram of the clamped state of the urethane resin injection mold of the present invention

[Figure 4] Conceptual diagram showing the state in which the floor carpet is depressed due to pressure

[Explanation of symbols]

1 Floor carpet material 1a Fiber layer 1b Backing material 2 Cushioning material 2a　Cushioning material general part 2b Cushioning material low density part 2c Cushioning material connection part 3 Injection upper mold 4 Lower injection mold 5 Cavity 6 Inlet 7 Pressing body 8 Floor panel

Claims (2)

[Claims] [Claim 1] A floor carpet to be laid on the floor panel of an automobile, wherein a pre-shaped floor carpet is placed on a pair of upper and lower foamed urethane resin injection molds with the back side facing upward and the molds are clamped. , in which a cushioning material mainly made of urethane foam is formed by injecting and foaming a urethane stock solution into the cavity.
The density of the cushioning material mainly made of urethane foam that is integrally formed on the back side of the carpet is 0.05 g/cm3.
A floor carpet for an automobile, characterized in that it is integrally formed with a general part having a density of 0.20 g/cm3 or more and a low density part having a density of 0.01 g/cm3 or more and less than 0.03 g/cm3. 2. The method for manufacturing an automobile floor carpet according to claim 1, wherein the cushioning material of the floor carpet comprises urethane foam having a density corresponding to the low-density portion according to claim 1 attached to the required part. The molded floor carpet was clamped with an upper mold until the cells of the urethane foam were substantially crushed, a foamable urethane resin stock solution was injected into the cavity and foamed to form a general part, and then the mold was opened and the above-mentioned adhesive was applied. A method for manufacturing an automobile floor carpet obtained by restoring the thickness of urethane foam to the thickness before mold clamping to form a low-density part integrally with a general part.