JPH04298309A - Manufacture of urethane-backed carpet - Google Patents
Manufacture of urethane-backed carpetInfo
- Publication number
- JPH04298309A JPH04298309A JP3085963A JP8596391A JPH04298309A JP H04298309 A JPH04298309 A JP H04298309A JP 3085963 A JP3085963 A JP 3085963A JP 8596391 A JP8596391 A JP 8596391A JP H04298309 A JPH04298309 A JP H04298309A
- Authority
- JP
- Japan
- Prior art keywords
- urethane
- carpet
- layer
- backing
- backing layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims abstract description 62
- 239000011324 bead Substances 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims abstract description 13
- 238000000465 moulding Methods 0.000 claims abstract description 7
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 239000006260 foam Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 5
- 230000002950 deficient Effects 0.000 abstract description 5
- 239000010410 layer Substances 0.000 description 25
- 239000002994 raw material Substances 0.000 description 10
- 238000013016 damping Methods 0.000 description 9
- 230000005484 gravity Effects 0.000 description 9
- 238000005187 foaming Methods 0.000 description 7
- 239000000835 fiber Substances 0.000 description 6
- 239000002356 single layer Substances 0.000 description 6
- 238000009413 insulation Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- -1 polypropylene Polymers 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 150000003673 urethanes Chemical class 0.000 description 1
Abstract
Description
【０００１】0001
【産業上の利用分野】本発明は、車両の床敷物（フロア
カ−ペット）等として使用されるウレタンバッキングカ
−ペットの製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing urethane backing carpets used as floor coverings for vehicles.
【０００２】0002
【従来の技術】従来、車両の車室床面に敷設して使用す
るフロアカ−ペットとして、カ−ペット材の裏面に発泡
ウレタンを裏打ちして弾力性を持たせたウレタンバッキ
ングカ−ペットが用いられている。このウレタンバッキ
ングカ−ペットは化学繊維又は、天然繊維で織成したカ
−ペット材を成形型内に置き、その上にウレタン原料を
投入、発泡成形し、ウレタンバッキング層を形成したも
のがある。そのウレタンバッキング層は、ウレタン層の
ものと、ウレタン層中に多孔鉄板等の制振材を埋め込ん
で振動抑制効果を持たせたものとがある。[Prior Art] Conventionally, urethane backing carpets, which are made by lining the back side of carpet material with foamed urethane, have been used as floor carpets laid on the floor surface of vehicle compartments. It is being This urethane backing carpet is made by placing a carpet material woven from chemical fibers or natural fibers in a mold, pouring a urethane raw material thereon, and foaming it to form a urethane backing layer. The urethane backing layer includes a urethane layer and a urethane layer with a damping material such as a porous iron plate embedded in the urethane layer to provide a vibration suppressing effect.
【０００３】図２は上記のような従来のウレタンバッキ
ングカ−ペットの製造工程を示した断面図である。図２
において１０はカ−ペットの成形形状に応じた所要の形
状を有する発泡成形型の下型でこの下型１０の成形面に
、化学繊維又は天然繊維で織成されたカ−ペット本体１
１の裏面（図示上面）には合成樹脂シ−トのマスバック
層１２が積層されている。FIG. 2 is a sectional view showing the manufacturing process of the conventional urethane backing carpet as described above. Figure 2
10 is a lower mold of a foam molding mold having a required shape according to the molded shape of the carpet, and a carpet body 1 woven from chemical fiber or natural fiber is placed on the molding surface of this lower mold 10.
A mass back layer 12 made of a synthetic resin sheet is laminated on the back surface (upper surface in the figure) of 1.
【０００４】このマスバック層１２はウレタンバッキン
グ層のカ−ペット本体１１への接着を良好ならしめるも
のである。次いでマスバック層１２の上に多孔鉄板等で
形成された制振材１３を置き、さらにその上から発泡材
を含有させたウレタン原料を投入して上型１４を覆装し
、ウレタン原料を発泡させて、ウレタンバッキング層１
５を形成させるものである。The mass back layer 12 allows the urethane backing layer to adhere well to the carpet body 11. Next, a damping material 13 made of a porous iron plate or the like is placed on the mass back layer 12, and then a urethane raw material containing a foaming material is put thereon, the upper mold 14 is covered, and the urethane raw material is foamed. Then, urethane backing layer 1
5.
【０００５】[0005]
【発明が解決しようとする課題】しかしながら、このよ
うな従来のウレタンバッキングカ−ペットの製造方法に
おいては、ウレタン単層の場合でも厚みの割合に重量が
大きいという欠点があり、とりわけ多孔鉄板等の制振材
を埋め込んだものは重量が大きくなり、また、ウレタン
原料を注入する際、カ−ペットが固定されていない為に
位置ずれが起き、不良品が生じるという問題点があった
。[Problems to be Solved by the Invention] However, in the conventional method for producing urethane backing carpets, even in the case of a single layer of urethane, there is a drawback that the weight is large in proportion to the thickness. Products in which damping material is embedded are heavy, and when the urethane raw material is injected, the carpet is not fixed in place, resulting in misalignment, resulting in defective products.
【０００６】本発明は上記の問題点に鑑みてなされたも
のであって、その目的とするところは、重量が小さく、
充分な制振性と遮音性を有し、しかもウレタン原料注入
の際の位置ずれから生じるウレタンバッキングカ−ペッ
トの不良品を防止することができるウレタンバッキング
カ−ペットの製造方法を提供することにある。The present invention has been made in view of the above problems, and its purpose is to reduce weight and
To provide a method for producing a urethane backing carpet that has sufficient vibration damping and sound insulation properties and can prevent defective urethane backing carpets caused by misalignment during injection of urethane raw materials. be.
【０００７】[0007]
【課題を解決するための手段】上記目的を達成する為に
本発明は、成形型内でカ−ペット本体の裏面と上型の成
形型面間の厚みより直径が大きい発泡ビ−ズを複数個配
置して、上型で押さえ付けて位置決めを行った後に、ウ
レタン原料を注入、発泡させて、ウレタンバッキング層
を形成するようにしたことを特徴とする。[Means for Solving the Problems] In order to achieve the above object, the present invention includes a plurality of foam beads having a diameter larger than the thickness between the back surface of the carpet body and the mold surface of the upper mold in the mold. After arranging and positioning by pressing with an upper mold, a urethane raw material is injected and foamed to form a urethane backing layer.
【０００８】[0008]
【作用】上記のように構成された本発明のウレタンバッ
キングカ−ペットの製造方法においては、ウレタンバッ
キング層に、発泡ビ−ズが複数個一体形成されているの
で、バッキング層がウレタン単層あるいは、ウレタン中
に制振材に埋め込んだものである場合に比し、重量が小
さく、減少するとともに、ウレタン原料注入の際に生じ
る位置ずれを防止し、制振性、遮音性に優れたウレタン
バッキングカ−ペットが得られる。[Function] In the method for manufacturing a urethane backing carpet of the present invention constructed as described above, a plurality of foamed beads are integrally formed in the urethane backing layer, so that the backing layer can be a single layer of urethane or a single layer of urethane. , a urethane backing that is smaller in weight than a damping material embedded in urethane, prevents misalignment that occurs when pouring urethane raw materials, and has excellent vibration damping and sound insulation properties. A carpet is obtained.
【０００９】[0009]
【実施例】以下、図面により本発明の実施例を図１に基
いて説明する。DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIG. 1 with reference to the drawings.
【００１０】図１は本発明方法におけるウレタンバッキ
ングカ−ペットの製造工程を示した断面図である。図１
において１はカ−ペットの成形形状に応じた所要の形状
を有する発泡成形型の下型で、この下型１の成形面に、
化学繊維または天然繊維で織成されたカ−ペット本体２
が敷置される。カ−ペット本体２の裏面（図示上面）に
は、合成樹脂シ−トのマスバック層３が積層されている
。FIG. 1 is a sectional view showing the manufacturing process of a urethane backing carpet according to the method of the present invention. Figure 1
1 is a lower mold of a foaming mold having a required shape according to the molding shape of the carpet, and on the molding surface of this lower mold 1,
Carpet body 2 woven from chemical fibers or natural fibers
is laid down. A mass back layer 3 made of a synthetic resin sheet is laminated on the back surface (upper surface in the figure) of the carpet body 2.
【００１１】次いで、マスバック層３の上に発泡ビ−ズ
４を複数個配置する。この発泡ビ−ズ４はポリプロピレ
ン、ポリエスチレン等の合成樹脂材を３０倍〜４０倍の
発泡倍率に発泡し、カ−ペット本体２の裏面と上型５の
成形面との間の厚みよりも直径が５％〜１０％の大きさ
の球状に予め成形させたものである。そして、上型５を
覆装することにより、発泡ビ−ズ４は圧縮され、マスバ
ック層３及びカ−ペット本体２を押さえつけ、位置決め
をしたのち、発泡材を含有させたウレタン原料を発泡剤
注入口６から注入し、加熱発泡させてウレタンバッキン
グ層７を成形させる。このように、本発明のウレタンバ
ッキングカ−ペットの製造方法は、従来のウレタン単層
、或いは、制振材をいれたウレタン層のものに比べて著
しく重量を軽減させたものとなる。すなわち、ウレタン
単層の場合ウレタンバッキング層７の比重は発泡ウレタ
ンの比重０．０８である。これに対し、本発明の製造方
法においては、発泡ビ−ズ４に例えばポリプロピレン材
を３８倍発泡させたものを使用する場合、ポリプロピレ
ンの比重は０．９４〜０．９６であるから、発泡ビ−ズ
４の比重は、０．９４÷３８＝０．０２５である。ウレ
タンバッキング層７のウレタンと発泡ビ−ズ４の混合比
率（容積比）を、ウレタン５５％、発泡ビ−ズ４５％と
すると、ウレタンバッキング層７の比重は、 （
ウレタン比重）０．０８ ×０．５５＝０．０４４
（ビ−ズ比重）０．０２５×０．４５＝０．
０１１
計０．０５５と
なり、ウレタン単層の場合に比し、同一厚みとした場合
のバッキング層の重量が約３割強軽減されることとなる
。この際、ウレタンの比重は０．０８〜０．１におさえ
また、発泡ビ−ズの比重は、０．０２４〜０．０３とす
る。このため、この軽減比率がさらに大きなものとなる
ことはいうまでもない。しかも、本発明の製造方法にお
いては、ウレタンバッキング層７内に防振遮音特性にす
ぐれた発泡ビ−ズ４が包含されており、また、ウレタン
発泡剤を注入した際の位置ずれから生じる不良品を防止
すると共に、従来のものに比してより優れた制振性、遮
音性が発揮される。Next, a plurality of foamed beads 4 are placed on the mass back layer 3. The foamed beads 4 are made by foaming a synthetic resin material such as polypropylene or polyethylene to a foaming ratio of 30 to 40 times, and are thicker than the thickness between the back surface of the carpet body 2 and the molding surface of the upper mold 5. It is preformed into a spherical shape with a diameter of 5% to 10%. Then, by covering the upper mold 5, the foamed beads 4 are compressed, and after pressing down and positioning the mass back layer 3 and the carpet body 2, the urethane raw material containing the foaming material is added to the foaming agent. It is injected through the injection port 6 and heated and foamed to form the urethane backing layer 7. As described above, the method of manufacturing a urethane backing carpet of the present invention can significantly reduce the weight compared to conventional urethane single layer or urethane layer containing vibration damping material. That is, in the case of a single layer of urethane, the specific gravity of the urethane backing layer 7 is 0.08, which is the specific gravity of urethane foam. On the other hand, in the manufacturing method of the present invention, when using polypropylene material expanded 38 times as the foamed beads 4, the specific gravity of polypropylene is 0.94 to 0.96, so the foamed beads 4 are - The specific gravity of the glass 4 is 0.94÷38=0.025. If the mixing ratio (volume ratio) of urethane and foam beads 4 in the urethane backing layer 7 is 55% urethane and 45% foam beads, the specific gravity of the urethane backing layer 7 is (
Urethane specific gravity) 0.08 x 0.55 = 0.044
(Bead specific gravity) 0.025 x 0.45 = 0.
011
The total weight is 0.055, and compared to the case of a single layer of urethane, the weight of the backing layer is reduced by about 30% when the thickness is the same. At this time, the specific gravity of the urethane is kept at 0.08 to 0.1, and the specific gravity of the foamed beads is kept at 0.024 to 0.03. Therefore, it goes without saying that this reduction ratio becomes even greater. Moreover, in the manufacturing method of the present invention, the foamed beads 4 having excellent vibration and sound insulation properties are included in the urethane backing layer 7, and defective products caused by misalignment when the urethane foaming agent is injected are In addition to preventing this, it also exhibits better vibration damping and sound insulation properties than conventional ones.
【００１２】0012
【発明の効果】以上のように構成された本発明のウレタ
ンバッキングカ−ペットの製造方法は、成形型内でカ−
ペット本体の裏面に、カ−ペット本体の裏面と上型の成
型面間の厚みより直径が大きい発泡ビ−ズを複数個配置
して上型で押さえつけて位置決めを行った後に、ウレタ
ン原料を注入、発泡させてウレタンバッキング層を形成
するようにしたので、従来のウレタンバッキングカ−ペ
ットに比して著しく重量を軽減し得る上、ウレタン原料
を注入する際の位置ずれから生じる不良品を防止すると
ともに優れた制振性と遮音性を有するウレタンバッキン
グカ−ペットを提供することができる。Effects of the Invention The method for manufacturing a urethane backing carpet of the present invention configured as described above is as follows:
Multiple foam beads with a diameter larger than the thickness between the back surface of the carpet body and the molding surface of the upper mold are placed on the back of the carpet body, and after positioning them by pressing them with the upper mold, the urethane raw material is injected. Since the urethane backing layer is formed by foaming, the weight can be significantly reduced compared to conventional urethane backing carpets, and it also prevents defective products caused by misalignment when injecting the urethane raw material. At the same time, it is possible to provide a urethane backing carpet having excellent vibration damping and sound insulation properties.
【図１】本発明の製造方法におけるウレタンバッキング
カ−ペットの製造工程を示した断面図である。FIG. 1 is a sectional view showing the manufacturing process of a urethane backing carpet in the manufacturing method of the present invention.
【図２】従来技術のウレタンバッキングカ−ペットの製
造工程を示した断面図である。FIG. 2 is a sectional view showing the manufacturing process of a conventional urethane backing carpet.
２ カ−ペット本体 ４ 発泡ビ−ズ ５ 上型 ７ ウレタンバッキング層 2 Carpet body 4. Foam beads 5 Upper mold 7 Urethane backing layer
Claims (1)
、カ−ペット本体の裏面と上型の成形面間の厚みより直
径が大きい発泡ビ−ズを複数個配置して上型で押さえつ
けて位置決めを行った後に、溶融ウレタン材を注入、発
泡させてウレタンバッキング層を形成するようにしたこ
とを特徴とするウレタンバッキングカ−ペットの製造方
法。[Claim 1] A plurality of foam beads having a diameter larger than the thickness between the back surface of the carpet body and the molding surface of the upper mold are arranged on the back surface of the carpet body in the mold, and 1. A method for manufacturing a urethane backing carpet, characterized in that after pressing and positioning, a molten urethane material is injected and foamed to form a urethane backing layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3085963A JPH04298309A (en) | 1991-03-27 | 1991-03-27 | Manufacture of urethane-backed carpet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3085963A JPH04298309A (en) | 1991-03-27 | 1991-03-27 | Manufacture of urethane-backed carpet |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH04298309A true JPH04298309A (en) | 1992-10-22 |
Family
ID=13873396
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3085963A Pending JPH04298309A (en) | 1991-03-27 | 1991-03-27 | Manufacture of urethane-backed carpet |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH04298309A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010092760A1 (en) * | 2009-02-12 | 2010-08-19 | クリナップ株式会社 | Method of producing resin molding, and resin molding |
-
1991
- 1991-03-27 JP JP3085963A patent/JPH04298309A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010092760A1 (en) * | 2009-02-12 | 2010-08-19 | クリナップ株式会社 | Method of producing resin molding, and resin molding |
| KR20110128798A (en) * | 2009-02-12 | 2011-11-30 | 크린업 코포레이션 | Method of producing resin molding, and resin molding |
| JP5441936B2 (en) * | 2009-02-12 | 2014-03-12 | クリナップ株式会社 | Manufacturing method of resin molded body, resin molded body |
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