JPH07223478A - Automobile floor carpet and its manufacture - Google Patents

Abstract

PURPOSE:To provide a lightweight automobile floor carpet excellent in sound insulation, etc., and a method for manufacturing it. CONSTITUTION:In an automobile floor carpat which has at least carpet pile a, a backing material 4 made of a thermoplastic resin laminated on the back side of the carpet pile a, and a layer 5 of cushioning material laminated on the back side of the backing material 4 and shaped to fit the floor panel of an automobile, the cushion material is a nonwoven fabric composed of synthetic fibers.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile floor carpet and a method for producing the same, and more particularly to an automobile floor carpet which is lightweight and has excellent sound insulation and a method for producing the same.

[0002]

2. Description of the Related Art In recent years, good sound insulation performance has been required for automobile floor carpets. In general, this floor carpet has a structure in which a carpet skin 1, a backing material 4, a cushioning material layer 5, a mel sheet 6, and a floor panel 7 are laminated in this order as shown in FIG.
The carpet surface and backing material are called the carpet layer).

Felt is often used as a cushioning layer in conventional floor carpets. Here, the felt is made by disintegrating used clothing into cotton and subjecting it to needle punching or adding a binder such as a phenolic resin to heat and curing it to give an apparent density of 0.04 to 0. A sheet-like material having a thickness of about 2 g / cm ³ and a thickness of about 5 to 30 mm.

However, since this felt has a poor shapeability and thus has poor adhesion to the floor panel (mel sheet), it generally has poor sound insulation performance. Also,
The unevenness due to the laid wire harness or the like may not be absorbed, and unevenness may occur on the carpet surface, which may cause a visual inconvenience. Further, there is a concern that the quality is not stable, sufficient sound insulation performance may not be obtained, and since the defibrated fibers contain natural fibers, there is a risk of generation of mold. in addition,
There is a drawback in that the fiber-to-fiber bond is weak and thus causes a fatigue over time.

In order to improve such a defect, a cushioning material using a urethane foam as a cushioning material in place of felt has been proposed (Japanese Utility Model Publication No. 59-126752). By shaping this urethane foam and using it as a cushioning material, the adhesion between the cushioning material and the floor panel is improved, and not only the sound insulation is improved, but the carpet surface is even and flat, which is excellent in appearance. Further, it has an effect of preventing the occurrence of aging and mold over time.

[0006]

However, when the urethane foam is used as the cushioning material, the material cost is high, and the process is complicated when it is adhered to the back surface of the floor carpet, which deteriorates the working environment. There is a problem.
In addition, in order to use the urethane foam, in addition to the carpet molding step, a liquid polyol and isocyanate injection step, a foaming step and an adhesion step are required.
The process takes time, and a large-scale facility including an exhaust facility is also required, resulting in poor productivity.
Further, since the urethane foam is hard under the condition that the load is not so heavy, it is not preferable as the performance of the cushioning material in consideration of the sound insulation theory of the double wall. As a countermeasure for this, the weight of the backing material is increased or a mass back is added to ensure sound insulation performance, but this is against the demand for weight reduction. In addition, urethane foam is difficult to recycle, which is not preferable even considering recent environmental problems.

Therefore, an object of the present invention is to enable the carpet layer and the cushioning material layer to be integrally formed by using a non-woven fabric made of synthetic fiber as the cushioning material. As a result, the working process can be simplified and It is an object of the present invention to provide an automobile floor carpet that can improve productivity and a method for manufacturing the same.

[0008]

Means for Solving the Problems As a result of intensive studies for solving the above problems, the present inventors have found that when a non-woven fabric made of synthetic fiber such as polyester fiber is used as a cushioning material, a carpet layer Since it is possible to perform integral molding with the cushioning material layer, large-scale equipment is not required, the working process can be simplified, and the productivity can be improved, and the present invention has been reached.

The above object of the present invention is to provide at least a carpet skin, a backing material composed of a thermoplastic resin laminated on the back surface of the carpet skin, and a floor panel shape of an automobile laminated on the back surface of the backing material. An automotive floor carpet having a shaped cushioning material layer, wherein the cushioning material is composed of a synthetic fiber non-woven fabric, and a method for producing the same. Hereinafter, the present invention will be described in more detail.

In the present invention, the fibers constituting the non-woven fabric can be appropriately selected from known synthetic fibers and used, but polyester fibers are preferably used from the viewpoint of cost and the like.

The cushioning material made of this polyester fiber is
The polyester fiber contains at least two kinds of fibers, that is, a high melting point polyester fiber and a low melting point polyester fiber, and is heated at a temperature above the melting point of the low melting point polyester fiber and below the melting point of the high melting point polyester fiber It is preferable to use a polyester fiber that can be shaped by fusion bonding and bonding between the fibers.

The difference in melting point between the above two types of polyester fibers is preferably 20 ° C. or more. Further, the low melting point polyester fiber to be fused is preferably one having a core-sheath structure. At 20 ° C. or lower, the high melting point fiber and the low melting point fiber are melted at the same time and molding becomes impossible. The melting point difference is not particularly limited because it does not cause a problem because it is too far apart, but 150 ° C
If it is separated from the above distance, the melting point of the low-melting point fiber is too low, which makes it difficult to handle and makes molding impossible.

The apparent density of the non-woven fabric forming the cushioning material layer is preferably in the range of 0.025 to 0.055 g / cm ³ . When the apparent density exceeds 0.055 g / cm ³ , not only the cost becomes high, but also the cushioning material becomes hard so that the performance as the cushioning material cannot be sufficiently exhibited, and it is against the demand for weight reduction. On the contrary, 0.025 g /
When it is less than ³ cm3, not only the sound absorbing performance is deteriorated but also the floor carpet is liable to be deteriorated, the durability of the floor carpet is deteriorated, and the cushioning property is also deteriorated, which is not preferable in the performance as a carpet.

The fineness of the fibers constituting the non-woven fabric is preferably in the range of 1.5 to 6 denier on average. If the fineness exceeds 6 denier on average, the sound absorbing performance tends to deteriorate, and therefore the sound transmission loss decreases. On the other hand, if it is less than 1.5 denier, the spinning speed is significantly reduced, and the line speed is also reduced in the non-woven fabric process, resulting in high cost.

Next, the manufacturing method of the present invention will be described. First, the automobile floor carpet of the present invention is shown in FIG.
The non-woven fabric is put into the forming die as shown in Fig. 1, the cushioning material made of the non-woven fabric that can be shaped in advance is pre-formed into the shape of the floor panel, and then the carpet layer is placed on the obtained pre-formed body before the die is formed. It is obtained by adhering a cushioning material to the backing resin by closing and heating, preferably hot pressing. Alternatively, the cushioning material is adhered to the backing resin by simultaneously putting the carpet and the non-woven fabric into the molding die on the temporary molded body, closing the mold and heating.

In the present invention, the carpet surface can be appropriately selected from known materials and used.
For example, needle punched carpet, tufted carpet and the like can be mentioned. Resins such as polyester, polyamide, polyacrylonitrile, and polypropylene are used as the material of the carpet skin. Latex treatment may be applied to the back surface of these carpet layers.

In the present invention, a thermoplastic resin such as EVA or low-density polyethylene is used to bond the carpet base cloth and the cushioning material layer, or a heat-bonded nonwoven fabric made of polyester fiber having a low melting point is used as an intermediate material. It may be inserted as a layer or may be directly laminated.

[0018]

EXAMPLES The present invention will be described in more detail below with reference to examples, but the present invention is not limited thereto.

Example 1 As the carpet 1, a normal carpet such as a needle punched carpet or a tufted carpet was used. As the carpet base cloth 2, a polyester spunbond base cloth was used. 3 is latex. EVA for the backing material 4
A thermoplastic resin sheet manufactured by the company was used. 5 is a cushioning material layer, the mel sheet 6 is an asphalt sheet,
It is usually heat-sealed to the floor panel 7.

As the cushioning material layer 5, a non-woven fabric was used in which 70% polyester fiber having a high melting point of 6 denier and 70% polyester fiber having a low melting point of 2 denier were mixed. Figure 2
As shown in A, the non-woven fabric 5 preliminarily heated to about 100 ° C. and shaped into a floor panel shape is put into a molding die, and the upper die 8
After the non-woven fabric is compressed by the lower mold 9 and temporarily molded into the shape of the floor panel, the carpet base cloth and the adhesive layer are sequentially placed on the temporary molded body obtained as shown in FIG. As shown in FIG. 2, the mold is closed again and main molding is performed at 130 ° C. to bond the cushioning material layer 5 to the back surface of the carpet base cloth.
As shown in D, the cushioning material layer 5 was molded so that the density and the thickness were 0.05 / cm ³ and 20 mm, respectively, to obtain the floor insulator shown in FIG. 1.

Since the floor insulator thus molded is molded in conformity with the shape of the floor panel, it has good fitting with the vehicle and good assembling workability. In addition, in the automobile floor carpet prototyped in Example 1, the carpet surface 1 has 0.6 kg / m ² ,
Carpet base cloth 2 is 0.125 Kg / m ² , latex 3 is 0.100 Kg / m ² , backing material 4 is 1.2 K
g / m ² (EVA), the nonwoven fabric 5 as the cushioning material layer is 1.0
Kg / m ² , 20 mm, Melsheet 6 is 5 Kg / m ² ,
3 mm (asphalt), floor panel 7 6.3 kg
/ M ² , 0.8 mm (steel plate).

Example 2 After molding a cushioning material layer in the same manner as in Example 1, except that 60% of high melting point polyester fiber of 6 denier and 40% of low melting point polyester fiber of 2 denier were blended. The cushioning material layer 5 was molded so that the density and the thickness thereof were 0.04 g / cm ³ and 20 mm, respectively, to obtain a floor insulator. The floor insulator molded in this manner had good fitting with the vehicle and good workability in assembly, as in the first embodiment. In the vehicle floor carpet of the present invention prototyped in Example 2, the cushioning material layer 5 was 0.8 Kg / m ² and 20 mm.

Comparative Example 1 As the sound insulation layer 5, a felt obtained by hardening fiber waste with a phenol resin was used, and its density and thickness were each 0.06 g / c.
A floor insulator was obtained in the same manner as in Example 1 except that the floor insulator was molded so as to have m ³ and 20 mm.
Assembling to the vehicle required a longer time for the work of laying the felt and the carpet skin separately and adhering them, as compared with Examples 1 and 2. The floor carpet for an automobile manufactured as a trial in Comparative Example 1 has a cushioning material layer 5 of 1.2 kg / m ² and 20 m.
It was m.

Comparative Example 2 Sheet-like urethane foam was used as the sound insulation layer 5, and its density and thickness were 0.06 g / cm ³ and 20 mm, respectively.
A floor insulator was obtained in the same manner as in Example 1 except that the floor insulator was molded so that As in Comparative Example 1, the assembly of the foamed urethane and the carpet skin separately on the vehicle, and the bonding work required a longer time than in Examples 1 and 2. Incidentally, in the automobile floor carpet prototyped in Comparative Example 2, the cushioning material layer 5 was 1.2 kg / m ² ,
It was 20 mm.

Comparative Example 3 The same urethane foam as in Comparative Example 2 was used as the sound insulation layer 5 and was integrally molded with the carpet. That is, after the carpet 1, the backing material 2, the latex 3, and the mass bag 4 are put into the foaming mold in a predetermined order, the urethane foam material is poured and integrally molded according to the shape of the floor panel of the vehicle. The density and thickness of the sound insulation layer are 0.06 each
It was molded to have g / cm ³ and 20 mm. The floor insulator produced by this method had good fitting with the vehicle and good assembly workability, but its sound insulation was lower than in Examples 1 and 2. The cushioning material layer 5 of the automotive floor carpet prototyped in Comparative Example 3 had a weight of 1.2 kg / m ² and 20 mm.

Table 1 shows the assembling workability, settling resistance and cushioning material density of the automobile floor carpets obtained in Examples 1 and 2 and Comparative Examples 1 to 3.

[Table 1]

FIG. 3 shows the results of measuring the sound transmission loss when the automobile floor carpets obtained in Examples 1 and 2 and Comparative Examples 1 to 3 were mounted on a vehicle. As shown in FIG. 3, it can be seen that the automobile floor carpets obtained in Examples 1 and 2 are superior in sound insulation as compared with those obtained in Comparative Examples 1 to 3.

[0028]

The interior material for automobiles and the method for producing the same according to the present invention have the following effects because they have the above-mentioned configurations. (1) A special bonding step for bonding the carpet layer and the sound insulation layer is unnecessary, and the bonding can be achieved at the same time when the sound insulation layer is formed. (2) Since the carpet layer and the sound insulation layer are integrally formed, it is not necessary to lay them separately, and the work steps can be reduced. (3) Since the sound insulation layer made of non-woven fabric with good shapeability can be molded according to the shape of the floor panel, it is easy to assemble and the adhesion with the floor panel is high. Not only does it provide excellent sound insulation, but it does not shift during use. (4) The integrally molded body has appropriate rigidity, and thus is easy to handle. (5) It does not require injection of raw materials to obtain a foam and time-consuming reaction molding process, so equipment is not large scale and no toxic substances are used, so the work process is improved and the process is speeded up. It (6) In the case of obtaining the same synthesis as urethane foam or felt with a non-woven fabric, the density of the cushioning material can be reduced by about 10 to 30%, so that the weight of the vehicle can be reduced.

[Brief description of drawings]

FIG. 1 is a basic configuration diagram of an automobile floor carpet.

FIG. 2 is a process drawing showing a molding method using a nonwoven fabric which is an embodiment of the present invention.

FIG. 3 is a diagram showing the results of measuring sound transmission loss when the floor carpets for automobiles obtained in Examples 1 and 2 and Comparative Examples 1 to 3 were attached to a vehicle.

[Explanation of symbols] 1 Carpet skin 2 Carpet base fabric 3 Latex 4 Backing material 5 Buffer layer or sound insulation layer 6 Mel sheet 7 Floor panel 8 Upper mold 9 Lower mold

Claims (4)

[Claims] 1. A backing material comprising at least a carpet skin, a thermoplastic resin laminated on the back surface of the carpet skin, and a cushioning material laminated on the back surface of the backing material and shaped into the shape of an automobile floor panel. An automobile floor carpet having a layer, wherein the cushioning material is composed of a synthetic fiber non-woven fabric. 2. The non-woven fabric is composed of polyester fibers, and contains at least two kinds of fibers, a high-melting point polyester fiber and a low-melting point polyester fiber, as a blend of the polyester fiber, and having a melting point higher than that of the low-melting point polyester fiber,
And by heating below the melting point of the high melting point polyester fiber,
2. The automobile floor carpet according to claim 1, wherein a cushioning material that can be shaped by using low melting point polyester fibers fused and bonded to each other is used. 3. The apparent density of the cushioning material layer is 0.025 to
The automobile according to claim 1 or 2, wherein the weight is in the range of 0.055 g / cm ³ , and the fineness of the fibers constituting the cushioning material layer is in the range of 1.5 to 6.0 denier on average. Floor carpet for. 4. The method of manufacturing an automobile floor carpet according to claim 1, wherein a buffer material layer formed of a non-woven fabric that can be shaped in advance is temporarily formed into a shape of the floor panel when the buffer material is bonded to the carpet. Molded, the resulting temporary molded body is placed in a carpet molding die, the carpet skin is put on the temporary molded body, the mold is closed, and the cushioning material layer and the carpet skin are heated. A method for manufacturing a floor carpet for an automobile, which is characterized by being bonded to enable simultaneous integral molding.