JPH06135280A - Method of applying pad material to carpet - Google Patents

Abstract

PURPOSE:To provide a method of applying a pad material to a carpet by one step in a short time with no risk of leakage of electromagnetic waves without use of adhesive. CONSTITUTION:The outer surface of pile 2 of a carpet 1 and a pad material 2 are pressed together, and in this condition, the carpet 1 and the pad material 2 are relatively reciprocated in a direction parallel to the contact surfaces thereof in short time intervals. Accordingly, the pad material made of thermoplastic material is softened and melted the side making contact with the pile 1a due to frictional heat generated by the slide motion of the carpet 1 and the pad material 2, and the pile 1a is embedded into the softened and melted thermoplastic material, thereby the carpet 1 and the pad material 2 are integrally incorporated with each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet-like pad material having flexibility such as a thermoplastic resin on a surface of a carpet laid on a floor of an automobile, that is, a required portion of a pile surface. The present invention relates to a method for sticking a pad material to a carpet, which sticks a pad.

[0002]

2. Description of the Related Art Conventionally, a pad has been attached to a surface of a carpet laid on a floor of an automobile, that is, a required portion of a pile surface. This is to attach a pad material to a portion that is significantly worn compared to other portions in the usage mode of the carpet that mainly organizes the fabric. For example, in a floor carpet, significant friction is caused. A heel pad material made of vinyl chloride resin is attached to the part where the heel of the driver to be rubbed (see 2 in Fig. 3) and the carpet is prevented from being locally worn. Is. Alternatively, various kinds of pad materials may be attached to a carpet used for a vehicle door trim or the like for the purpose of design.

There are two conventional methods for attaching pad materials for carpets. One is a method of adhering by using an adhesive such as hot melt as described in Japanese Utility Model Publication No. 63-26976, that is, a pad material and a bead shape on the back surface of the pad material. The hot-melt adhesive applied to the, and a carpet pressed on the back surface of the pad on the pile surface via the hot-melt adhesive, the hot-melt adhesive in a state of being heated and melted. By being applied to the back surface of the pad material and being pressed onto the pile surface before solidifying, it is flowing at the root of the pile, and the pad material and carpet are fixed and sealed at the outer periphery of the pad material. This is a characteristic sticking method.

Other application methods do not use adhesives and use some physical method to provide padding and / or carding.
It is a sticking method in which the surface layer of the pet is softened by heating and pressure-bonded to the carpet.

According to the latter sticking method, since no adhesive is used, the cost can be reduced and the application process of the adhesive can be omitted. Typical examples of the latter attachment method include high-frequency welding and ultrasonic welding. High frequency welding uses a high frequency dielectric heating phenomenon on a resin with a high dielectric power factor, sandwiches a pad material and a carpet made of a thermoplastic resin between electrodes, applies a high frequency voltage and presses to weld the pad material. Is the way.

The problem with the high-frequency welding method is that the electrode portion is exposed and the output is large, so that the high frequency leaks and may cause malfunction in other production equipment in the factory. In addition, it is necessary to install a shielding wall that shields this high frequency leakage. Furthermore, if the voltage between the electrodes is large, electric discharge may occur during welding, and the thermoplastic resin may be destroyed.

Ultrasonic welding applies a phenomenon in which heat is generated by internal friction when ultrasonic vibration is applied to a viscoelastic body such as a thermoplastic resin, and a dozens of tens are formed by a pressurizing body called a horn. Apply vibration of frequency μm to several tens μm of K to several hundreds K HZ,
This is a method of welding the pad material.

The problem with the ultrasonic welding method is that the size of the horn is limited, and when the horn becomes large, it becomes difficult to vibrate uniformly over the entire surface of the horn.
It cannot be welded at once.

[0009]

DISCLOSURE OF THE INVENTION The present invention is a sticking method for sticking a thermoplastic resin pad material to the carpet without using an adhesive, which solves the above problems.

[0010]

SUMMARY OF THE INVENTION According to the present invention, a pad material is pressed against a pile surface of a carpet, and in this pressed state, the carpet and the pad material are parallel to their mutual contact surfaces at short intervals. And the relative reciprocating motion, and the frictional heat generated by the sliding of both the carpet and the pad material softens and melts the thermoplastic resin of the pad material on the side in contact with the pile. A pad material is attached to a carpet by embedding a pile material in a plastic resin to integrate the carpet and the pad material.

[0011]

Since the present invention has the above-described structure, the pad material is pressed against the pile surface of the carpet, and the carpet and the pad material are pressed against each other at a short time in this pressed state. The reciprocating motion is performed in parallel with the contact surface, and frictional heat generated by the sliding of both the carpet and the pad material softens and melts all the thermoplastic resin of the pad material on the side in contact with the pile. By embedding a pile material in the softened and melted thermoplastic resin, it is possible to firmly adhere to the carpet in a single step without using an adhesive and in a short time. Further, at this time, there is no factor such as leakage of electromagnetic waves, which causes an external obstacle.

[0012]

EXAMPLE An example of a method for attaching a pad material to a carpet of the present invention will be described below with reference to the drawings.
FIG. 1 shows an embodiment of a method of attaching a pad material to a carpet of the present invention. This is a method of attaching the pad 2 to the carpet 1 on the floor of the automobile as shown in FIG. The carpet 1 is usually a pile 1a on the surface as shown.
And a base fabric 1b as an intermediate layer and a backing 1c as a back surface layer are integrated into three layers. The pad material 2 is pressed against the surface of the pile 1a of the carpet 1, and in this pressed state, the carpet 1 and the pad material 2 are parallel to each other's contact surfaces at a short time interval and relatively. The thermoplastic resin of the pad material 2 on the side in contact with the pile 1a is softened and melted by the frictional heat generated by the reciprocating motion and the sliding of the carpet 1 and the pad material 2 to form a softened and melted thermoplastic resin. On the other hand, the attaching method is characterized in that the pile material 2 is embedded to integrate the carpet 1a and the pad material 2.

Blasting was applied in order to prevent the carpet 1 and the pad material 2 from shifting. A pad material 2 made of a thermoplastic resin, that is, a soft vinyl chloride resin is placed on the metal weld mold W. The pad material 2 is
Thickness: 1 mm, vertical x maximum size: 220 x 1
It is 20 mm. The weld type W has a size corresponding to that of the pad material 2, and has a ridge corresponding to a welded portion on the outer peripheral portion and inside although not shown. Further, a guide piece G for preventing the pad material 2 from being displaced is arranged on the outer periphery of the weld mold w.

The carpet 1 is placed from above the weld die W on which the pad material 2 is placed, and a pressing die 6 applies pressure. Example 1, that is, the carpet 1 is a loop pile tufted carpet in which polypropylene fiber naps are arranged in a loop on a polyester spunbond base cloth 1b.
The pet 1 has a backing 1c made of low-density polyethylene resin on the back surface. Textile weight of fiber is 350 / m
Become ² . The welding condition is an amplitude under a pressure of 310 kgf:
After giving horizontal vibration at 1.2 mm and frequency: 240 Hz for 4 seconds, stop the vibration and do 6se at 1,156 kgf.
The welding is completed by performing compression between c.

In this type of carpet 1, a cushioning material 3 such as a foul or urethane foam is often provided on the back surface.
When the vibration and pressure applied to the carpet 1 do not sufficiently act, this portion is separated by the double-sided tape 4 with the release paper 5 and after the pad material 2 is attached. , Fig. 2
As described above, the release paper 5 can be peeled off and attached.

Table 1 below shows the details of the test results of Example 1 and Example 2 to Example 7 in which the pad material 2 was applied to the carpet 1 under different welding conditions. There is.

[0017]

[Table 1]

Regarding the weldability of the pad material 2 of the example, Table 1
As described above, the adhesive strength and the appearance were evaluated. The adhesive strength was evaluated as a peel strength of 25 mm parallel to the welding line. With conventional high frequency welding, 7.5 to 12 kg
Since it is f, it can be evaluated as good because it has an adhesive strength equal to or higher than this. Regarding the appearance, the condition was that the surface of the pad material 2 (weld type W side) was not damaged by significant friction. In Table 1, ⊚: very good, ◯: good, Δ: fair, ×: bad.

From the results shown in Table 1, when vibration welding at 240 Hz was performed under a pressure of 310 kgf, the amplitude was 3 m.
When it exceeds m, the surface of the pad material 2 is damaged and the amplitude is 2
It can be understood that it is preferably mm or less. Also, the pressure after vibration is preferably around 1000 kgf.
If it is less than 00 kgf, the adhesive strength will be insufficient and 2000
It has been proved that there is a danger of perforating the pad material 2 if it exceeds kgf.

By considering the above conditions, the pad material 2 can be suitably attached to various carpets 1.

[0021]

The method of attaching the pad material to the carpet of the present invention has the above-mentioned constitutions, and therefore has the following effects. 1. The pad material can be attached to the carpet in a short time in a single process. 2. Since no adhesive is used, the cost is reduced and no adhesive coating equipment is required. 3. Since there is no leakage of electromagnetic waves, there is no need to provide a shielding wall without causing a malfunction in other production equipment in the factory. 4. It can be attached even if the carpet is wet, and trimming by a water jet as a pre-process of this type of carpet is possible.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a method of attaching a pad material to a carpet of the present invention.

FIG. 2 is a sectional view showing the cushioning material after the pad material is adhered.

FIG. 3 is a perspective view showing a state in which a pad material is attached to a carpet on a floor of an automobile.

[Explanation of symbols]

 G ... Guide piece W ... Weld type 1 ... Carpet 1a ... Pile 1b ... Base cloth 1c ... Lining 2 ... Pad material 3 ... Buffer material 4 ...・ Double-sided tape 5 ・ ・ ・ Release paper 6 ・ ・ ・ Pressing die

Claims (1)

[Claims] 1. A pad material is pressed against the pile surface of a carpet, and in this pressed state, the carpet and the pad material are parallel to each other's contact surface at a short time interval and are relatively reciprocated. The thermoplastic resin of the pad material that is in contact with the pile is softened and melted by the frictional heat generated by the movement and sliding of the carpet and the pad material, and the pile material is applied to the softened and melted thermoplastic resin. A method for adhering a pad material to a carpet, characterized by integrating the carpet and the pad material by embedding.