JPH08238703A - Car mat and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide a unique design and improve the fabricating and mounting workability for a heel pad by forming a synthetic resin or rubber lining layer on a base cloth tufted by a piled yarn and laying a golden and silver thread coated with a metal thin film into a part of the synthetic resin film. CONSTITUTION: A lining layer 8 is provided on the rear side of a base cloth 1 tufted by a piled yarn. In addition, a golden and silver thread 4 is laid into the piled yarn 2. Thus the metallic luster of the golden and silver thread 4 is added to the color tone of the piled yarn 2, so that the surface of a car mat is brilliant uniquely like a lame pattern displaying a superb design. A vapor deposition method uses a fixing means of a high frequency welder from a viewpoint of fabrication efficiency. That is, the car mat with a thick sheet for a heel pad deposited on a specified position of a piled yarn implanted face, is arranged on the table plate of the welder, and a high frequency electric field is applied to the car mat in such a state that the thick sheet is pressed from above through a die provided on a lift plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufted carpet type car mat to be laid on the floor of an automobile and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a car mat, there is a tufted carpet type in which a backing layer of synthetic resin or rubber is provided on the back surface of a base fabric tufted with pile yarns.
The color tone of this kind of car mat is set variously by dyeing after tufting (post-dyeing) and coloring of the pile yarn itself to be used. Depending on the combination of pile yarns with different shades, there are some patterns such as spots and stripes. Although it can be attached, there has been a drawback that the conventional design is poor in design.

In view of the above-mentioned circumstances, the present invention has an object to provide a car mat in the form of a tufted carpet, which has a unique design property which has never been obtained and which is excellent in workability for attaching a heel pad. There is.

[0004]

In order to achieve the above object, in the car mat according to the invention of claim 1, a backing layer 3 made of synthetic resin or rubber is provided on a base cloth 1 tufted with pile threads 2. A structure is adopted in which a gold-silver thread 4 having a synthetic resin film coated with a metal thin film is twisted into at least a part of the pile thread 2.

According to a second aspect of the present invention, in the car mat of the first aspect, the gold and silver thread 4 is an insulating gold and silver thread having a discontinuous metal thin film.

According to a third aspect of the present invention, in the car mat according to the first or second aspect, the metal thin film of the gold and silver thread 4 is Sn or S.
It employs a structure made of an n alloy.

According to the invention of claim 4, the pile yarn 2 in which the insulating gold-silver yarn 4 of claim 2 is twisted is tufted on the base fabric 1, and the back surface thereof is lined with a synthetic resin or rubber, A car mat manufacturing method characterized in that a heel pad 5 and / or a name plate 6 made of synthetic resin or rubber is welded to the front surface side by high frequency heating.

[0008]

Detailed Structure and Operation of the Invention FIG. 1 shows the basic structure of a car mat according to the present invention. In the figure, 1 is a base cloth, 2 is a pile thread tufted on the base cloth 1, 3 is a backing layer provided on the back side of the base cloth 1, and a gold and silver thread 4 is twisted into the pile thread 2. It is rare. In such a car mat, however, the metallic luster of the gold and silver yarns 4 is added to the color tone of the pile yarns 2, so that the matte surface exhibits a unique glittering shine, and thus has an unprecedented excellent designability. Demonstrate.

The gold and silver thread 4 is made of a synthetic resin film coated with a metal thin film. This is polyester such as polyethylene terephthalate, rigid polyvinyl chloride,
Polyolefins such as polypropylene and polyethylene,
Vacuum deposition, ion plating, sputtering, CVD on synthetic resin film such as polyamide (nylon)
A thin metal film with a thickness of several tens of Å to 1,000 Å is applied by a thin film forming technique such as a chemical vapor deposition method, etc., and this film is used as it is, or after two sheets are bonded together, it is made into a thin thread by a micro slitter Cutting (generally 30.3 mm
= 80 to 100 equal parts of 1 inch), or this flat gold and silver thread as a core thread of rayon thread, nylon thread, polyester thread, etc. at a rate of about 20 to 2000 times / m, and a haori coat twist, It is a twisted gold-silver yarn twisted by an appropriate method such as a bellows twist or a twist twist. In addition, as such gold and silver thread, generally, vacuum deposition (vacuum degree 10 ⁻⁴ To
The mainstream is a metal thin film formed by about rr), but an undercoat layer of an appropriate resin is interposed under the metal thin film, a transparent protective layer formed by coating or sticking a film of the appropriate resin on the metal thin film. Alternatively, the gold-silver thread of the present invention naturally includes a colored protective layer provided with various colors such as gold with a dye or the like.

However, as the metal thin film of the above-mentioned gold-silver thread 4, Al, Ag, Sn, Cu, Cr, Pb, Zn and B are used.
Examples thereof include i, Ti, Fe, Co, Ni, and alloys thereof. In particular, in the present invention, Sn or Sn alloy is recommended. That is, in a car mat, a pile yarn 2 is tufted on a base fabric 1 and then a required dyeing process is often performed by a post-dyeing process. There is a drawback that it cannot withstand dyeing processing such as. On the other hand, the gold-silver yarn having a thin film of Sn or Sn alloy has the advantages that it is excellent in the resistance to the dyeing process and is inexpensive. As the Sn alloy, Sn-Al alloy and Sn-Si alloy are suitable.

On the other hand, a car mat may be attached with a heel pad made of a thermoplastic resin such as polyvinyl chloride or rubber at a position where the heel of the occupant hits. Especially, a car mat with a heel pad is often used for a driver's seat. Has been done. Further, in order to display the brand name and the manufacturer name, a name plate made of the same thermoplastic resin or rubber is often attached alone or together with the heel pad. Then
In the tufted carpet type car mat according to the present invention, as shown in FIG. 2, the heel pad 5 and the name plate 6 are fixed to the planting surface of the pile yarn 2. As the fixing means, from the viewpoint of processing efficiency, a welding method using a high-frequency welder, that is, a car mat on which a thick sheet for heel pad is placed at a predetermined position on the pile yarn planting surface is placed on the base plate of the welder and lifted. A high-frequency electric field is applied to the thick-walled sheet from above through a die provided on the plate to soften and melt the thick-walled sheet by dielectric heating, and thus the pile yarn planting surface of the heel pad. It is preferable to use a method in which the welding to the surface and the molding of the surface (concavo-convex patterning) are performed simultaneously.

However, when the ordinary gold-silver thread 4 is twisted into the pile thread 2, the gold-silver thread 4 exhibits conductivity due to the metal thin film, so that the heel pad 5 and the name plate 6 are welded by the above high-frequency welder. At this time, there is a problem that the electric charge of the gold and silver yarns charged at a high frequency causes discharge, and the spark damages the car mat. Therefore, in a car mat in which the heel pad 5 and the nameplate 6 are welded by high frequency heating, it is preferable to use an insulating gold-silver thread having a discontinuous metal thin film as the gold-silver thread 4. This insulating gold and silver thread is obtained by cutting a metal vapor deposition film as disclosed in, for example, Japanese Patent Publication No. 6-6833, and since the metal thin film has a sea-island structure separated from each other on the synthetic resin film. Despite having metallic luster, it does not exhibit conductivity and does not generate sparks even when a high frequency electric field is applied.

As the above-mentioned insulating gold-silver thread, the island size of the metal thin film having a sea-island structure is 200Å to 1 μm.
The distance between islands is preferably about 100 to 5000Å, and if the islands are too large or the islands are too small, discharge may occur during high frequency heating.
On the other hand, if the islands are too small or the distance between the islands is too large, the metallic luster becomes poor. Also in such insulating gold-silver yarn, it is recommended that the metal thin film is made of Sn or Sn alloy.

As the pile yarn 2 in which the gold and silver yarn 4 is twisted,
Polyamide (nylon), polyester, polypropylene, polyacryl, wool and other commonly used pile yarns for car mats can be used without any problems, and the thickness is 300
About 5,000 denier is preferable, and the coloring may be any of dying (excluding wool), dyeing and dyeing. Then, the gold-silver thread 4 is preferably twisted in advance with respect to the pile thread 2 as described above, and is preferably entangled with, for example, 20 to 26.
It may be twisted at a rate of 0 times / m. The pile yarn 2 in which the gold and silver yarn 4 is twisted may be heat set.

As the base cloth 1, polyester non-woven fabric, polyolefin non-woven fabric, polyester tape yarn woven fabric,
Polyolefin tape yarn woven fabric and the like are suitable. And tuft conditions are 5/32, 1/8, 1/10, 5/6
All gauges generally used for tufted carpets such as 4 gauge can be applied.

The backing layer 3 imparts size and shape stability of the car mat, pile yarn fastening property, anti-slip function and the like, and is made of rubber or synthetic resin and tufted with the pile yarn 2. On the back side of 1 (toughed fabric), the sheet-like material is laminated and integrated by thermocompression bonding or adhesion, melt coating, or the like. Then, in the backing layer 3,
Various additives such as colorants and fillers may be included.

Although FIG. 1 shows an example in which the pile yarn is a cut pile, it may be a loop pile.
Further, in the car mat of the present invention, it is not necessary that all of the pile threads tufted on the base fabric are twisted with gold and silver threads, and pile threads containing gold and silver threads and pile threads not containing gold and silver threads are used. The combination may be used, and the combination ratio can be freely set. In addition, the overall shape of the car mat,
The shape of heel pads and nameplates, and the density and length of pile yarns can be set freely.

The procedure for producing a car mat is not particularly limited, but in general, tufting of pile yarn to a base fabric → dyeing (as necessary) → sealing treatment → size of mat unit Rough cutting → Lining → Die cutting into the final car mat shape → High frequency welder processing with heel pad and name plate → Overlock processing to protect the peripheral edge of the mat. In addition, the above-mentioned sealing treatment is to apply the rubber or the like to the back surface of the tufted fabric so that the pile yarn does not easily come off from the base fabric.

[0019]

[Example] Using a tufting machine, a polyethylene terephthalate non-woven fabric having a thickness of 0.56 mm
Three sets of three denier nylon yarns are twisted 180 times / mS and then three sets are twisted together for 130 times / mZ, and two sets of 1225 denier nylon yarns are twisted to twist an insulating gold-silver yarn. The set yarn twisted and twisted 50 times / mZ is alternately tufted in stripes at a ratio of the former / latter of 4/1, after-dyed, and styrene-butadiene rubber is applied to the back side of the fabric. Then, the cut pile fabric for car mats in which the twist ratio of the gold and silver yarn in the pile yarn was 2.4% was produced. This fabric is 5/3
2 gauge cut pile, 8.2 stitches, pile height 1
It was 7 mm. The gold and silver thread has a thickness of 12 μm.
The size of islands is about 1000Å and the spacing between islands is 100Å by semi-continuous vacuum deposition on polyethylene terephthalate film.
A Sn vapor deposition film having a sea-island structure is formed, and a transparent protective layer having a thickness of 2 μm is provided on the vapor deposition surface side of the film with an acrylic-melamine resin.
What was cut so as to divide 0.3 mm (1 inch) into 80 equal parts was used.

Next, a rubber sheet was thermocompression bonded to the back side of the cut pile fabric to form a backing layer having a thickness of 2.0 mm, which was then cut into a car mat shape (55 cm × 72 cm), and then the front side. By placing a polyvinyl chloride sheet (11 cm x 18 cm) for heel pad and a polyvinyl chloride piece (3 cm x 10 cm) for nameplate at a predetermined position, and applying a high frequency electric field to the sheet under pressure with a high frequency welder, the heel Weld and mold pads and nameplates,
An overlock process was performed to produce a car mat. The obtained car mat had a unique lame-like surface in which innumerable glittering parts were scattered throughout, and had an outstanding design property that has never been obtained. Moreover, no damage due to sparks occurred at the time of welding and forming the heel pad.

[0021]

According to the invention of claim 1, as a car mat in which a backing layer is provided on a base fabric tufted with pile yarns, a metal thin film is attached to a synthetic resin film on at least a part of the pile yarns. The twisted gold and silver threads add the metallic luster of the gold and silver threads to the color of the pile threads, and the surface shows a unique glittering shine, which is a design that has never been seen before. Will be provided.

According to the second aspect of the present invention, in the car mat, since the gold and silver yarn twisted into the pile yarn is an insulating gold and silver yarn, a heel pad made of synthetic resin or rubber by high frequency heating on the mat surface, Provided is one capable of welding nameplates without fear of damage due to sparks, thereby achieving high production efficiency.

According to the third aspect of the present invention, since the metal thin film of the gold-silver yarn is Sn or Sn alloy in the car mat, it is possible to perform post-dyeing by high-pressure dyeing or reaction dyeing after tufting pile yarns. Therefore, it is possible to provide a variety of colors and patterns.

According to the fourth aspect of the present invention, in particular, a car mat having a heel pad and a name plate made of synthetic resin or rubber on the surface where the pile yarn is planted can be manufactured with high production efficiency and without causing damage.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view of a main part showing a basic configuration of a car mat of the present invention.

FIG. 2 is a plan view showing one form of the car mat.

[Explanation of symbols]

 1 Base cloth 2 Pile thread 3 Lining layer 4 Gold and silver thread 5 Heel pad 6 Name plate

 ─────────────────────────────────────────────────── --- Continuation of the front page (72) Inventor Masanori Fujiwara 5-125 Higashiarioka, Itami-shi, Hyogo Tori Co., Ltd.

Claims (4)

[Claims] 1. A backing layer made of synthetic resin or rubber is provided on a base fabric tufted with pile yarns, and a gold-silver yarn having a synthetic resin film coated with a metal thin film is twisted into at least a part of the pile yarns. A car mat that is characterized by 2. The car mat according to claim 1, wherein the gold-silver thread is an insulating gold-silver thread having a discontinuous metal thin film. 3. The car mat according to claim 1, wherein the metal thin film of the gold and silver thread is made of Sn or Sn alloy. 4. The pile yarn in which the insulating gold-silver yarn according to claim 2 is twisted, is tufted on a base cloth, and the back surface is lined with a synthetic resin or rubber, and then the front surface side is made of a synthetic resin or rubber. A method for producing a car mat, comprising: welding a heel pad or / and a name plate made of the same by high frequency heating.