JPH08238967A - Manufacture of carpet - Google Patents

Abstract

PURPOSE: To reduce material and simplify a machining process by placing a molded shape retaining layer, formed by mixing melting fiber in regular fiber at a high ratio and kept in fixed shape after being hardened by heat treatment, on top of a cushioning-damping layer with melting fiber mixed in regular fiber at a low ratio, and after heating each layer, applying cooling press to both layers. CONSTITUTION: A cushioning-damping layer A is formed by mixing melting fiber 1 in regular fiber 2 at 50wt.% or less, for instance, desirably about 20wt.%. A molded shape retaining layer B with melting fiber 1 mixed in regular fiber 2 at 50wt.% or more, for instance, desirably about 80wt.% is disposed on the upper face of the cushioning-damping layer A. After the cushioning-damping layer A and the molded shape retaining layer B are heated at the melting point of the melting fiber 1 or higher, and at the melting point of the regular fiber 2 or lower, both layers A, B are placed between the upper and lower molds X, Y of a cooling press and pressure-welded from the molded shape retaining layer B side. Welded parts M are thereby formed so as to integrate both layers A, B through the melting fiber 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to a method for manufacturing a carpet laid on a floor panel or the like of an automobile.

[0002]

2. Description of the Related Art Tuft carpets and needle punch carpets are laid on the floor of a vehicle. These carpets are composed of a composite, for example, a needle-punched carpet such as polypropylene that serves as a skin layer, a mixed layer of latex and fibers located directly below the carpet, a polyethylene molding layer in the middle part, and a vibration damping and soundproofing layer that is the bottom layer. It is composed of each layer of the felt layer. The needle punch carpet having the composite structure is manufactured through the following steps.

(1) A step of needle-punching a web of fibers to produce a needle-punched carpet.

(2) A step of applying latex to the back surface of a needle punch carpet to hold fibers.

(3) A step of applying polyethylene to the back surface of the needle punch carpet to form a polyethylene sheet.

(4) Process of manufacturing felt.

(5) A step of punching a felt according to a mold.

(6) A heated needle punch carpet is provided on the die-cutting felt layer provided in the press die, and when the polyethylene sheet is in a molten state, it is cold-pressed into a floor panel shape polyethylene sheet. And the process of forming needle punch and crimping felt.

As described above, in the general carpet, after the needle punched carpet which is the surface layer is manufactured, polyethylene is applied to the back surface (latex layer) of the carpet and the felt is adhered by the anchor effect simultaneously with the press molding. .

[0010]

However, the above-mentioned conventional carpet manufacturing method involves a large number of manufacturing steps, resulting in a high processing cost.

In view of the above, according to the present invention, the needle punch carpet itself has a shape-retaining property, and at the same time, the cushioning performance and the vibration damping performance of the felt are imparted to reduce the amount of material and simplify the working process. Is intended.

[0012]

In order to solve the above-mentioned problems and to achieve the object, the method for producing a carpet according to the present invention is such that a regular fiber is added to a buffer / vibration layer in which melt fibers are mixed at a low rate. The method is characterized by including a step of superimposing a shape-retaining layer having regularity after the melt fibers are mixed at a high rate and curing by heat treatment, and a step of cooling and pressing after heating each layer. In this case, the shape-retaining layer plays the role of a skin.

A step of stacking the shape-retaining layer on the cushioning / damping layer, and a step of stacking an uppermost layer in which regular fibers are mixed at a low ratio on the shape-retaining layer; And a step of cold pressing after heating each of the layers. In this case, the uppermost layer is a fibrous skin.

As a pre-stage of heating the stacked layers, a step of subjecting the layers to needle-punching to entangle the fibers may be added.

Specifically, the regular fibers are synthetic fibers such as polyester and polypropylene, natural fibers such as cotton and wool, or anti-wool of each of the fibers, and the melt fiber is a polyester-based low fiber. Melting point fiber,
When the olefin low melting point fiber or the regular fiber is a natural fiber such as polyester fiber, cotton or wool,
It is characterized by being polypropylene fiber having a lower melting point than that.

[0016]

[Function] Even if the buffer / damping layer having a low melt fiber ratio and the molded shape retaining layer having a high melt fiber ratio are heated in the same manner, due to the difference in the mixing ratio of the melt fibers, At the confounding points, the welded portions are scattered and formed, and the buffer / vibration damping layer as a whole has appropriate elasticity. On the other hand, in the shape-maintaining layer, as a result of the high density formation of the welded portion, the shape-maintaining layer becomes a hard plate as a whole.

The present invention utilizes the difference in the properties of both layers depending on the mixing ratio of the melt fiber.
After stacking both layers, the steps of needle punching, heating and pressing are performed as a whole to easily form a layer having a cushioning / vibrating action and a layer having a shape-retaining action.

[0018]

EXAMPLES Next, referring to FIGS. 1 (a) to 1 (d),
A first embodiment of the present invention will be described. This carpet manufacturing method is characterized by having the following steps (1) to (3).

(1) As shown in FIG. 1 (a), the regular fiber 2 and the melt fiber 1 are, for example, 50 by weight.
% Or less, preferably about 20% is mixed to form the buffer / damping layer A. Here, "regular fiber" includes synthetic fibers such as polyester and polypropylene, or cotton, natural fibers such as wool, or anti-wool thereof,
"Melt fiber" is a low melting point fiber of polyester or olefin, and a polypropylene fiber having a lower melting point (melting temperature) when the regular fiber 2 is a natural fiber such as polyester fiber, cotton or wool. And so on. In short, the regular fiber and the melt fiber are relative concepts, and the fibers having a melting point lower than that of the regular fiber 2 are collectively referred to as the melt fiber 1
Say. The melt fiber 1 also includes so-called core-sheath fiber in which the core of regular fiber is covered with the sheath of melt fiber.

(2) As shown in FIG. 1B, the melt fiber 1 is mixed with the regular fiber 2 on the upper surface of the buffer / damping layer A in a weight ratio of, for example, 50% or more, preferably about 80%. The shape-retaining layer B is provided.

(3) As shown in FIG. 1C, after heating the buffer / damping layer A and the shape-retaining layer B above the melting point of the melt fiber 1 and below the melting point of the regular fiber 2, they are cooled. It is placed between the upper and lower molds X and Y of the press, and the layers A and B are pressed from the side of the shape-maintaining layer B while being cooled.

In the carpet manufactured through the above steps (1) to (3), the heated melt fiber 1 is the regular fiber 2 of the buffer / vibration layer A and the regular fiber 2 of the shape-retaining layer B. A welded portion M is formed at the confounding point with. Further, the two layers A and B are integrated at the mutual boundary surface via the melt fiber 1 as a medium.

When the mold shape-retaining layer B is cured by cooling the molds X and Y to room temperature, the entire carpet is held in a stable predetermined shape as shown in FIG. 1 (d). As a result, according to the present embodiment, the step of holding the back surface of the needle punch with latex and welding the mixed layer of latex and fibers with a polyethylene sheet as in the prior art is unnecessary. Therefore, it becomes possible to manufacture the carpet at an extremely low cost by reducing the material and omitting the processing steps. Further, by adjusting the thickness and weight of the cushioning / damping layer A, it is possible to improve the cushioning performance against impacts to the same level as a general carpet.

Next, a second embodiment of the present invention will be described with reference to FIG. This carpet manufacturing method is
As a pre-heating step in the first embodiment, FIG.
From the side of the shape-retaining layer B, as described above,
There is a step of applying the needle punch N while adjusting the thickness and the density. The other steps are the same as those in the first embodiment, and the description thereof will be omitted.

For example, the cushioning / vibration layer A and the shape-maintaining layer B are made to have a thickness ratio of about 2: 1, and a needle punch N is applied from the side of the shape-maintaining layer B to form both layers A, Entangling the melt fiber 1 and the regular fiber 2 of B,
The thickness ratio is finally adjusted to about 3: 1.

As shown in FIG. 2 (d), the carpet completed according to this embodiment has the cushioning / vibration damping layer A that does not become so thin that the overall thickness of the carpet can be reduced without lowering its ability to absorb vibrations and the like. In addition, the shape of the carpet can be firmly held in a predetermined shape by the shape-retaining layer B entangled with high density by needle punching. The needle punch N can be applied from the side of the buffer / damping layer A.

Next, a third embodiment of the present invention will be described with reference to FIG. This carpet manufacturing method is
It is characterized in that the following steps (5) and (6) are provided after the steps (1) and (2) of the first embodiment.

(5) As shown in FIG. 3A, the regular shape fiber 2 and the melt fiber 1 are formed on the upper surface of the shape-retaining layer B.
The uppermost layer C having a weight ratio of 50% or less, preferably about 20%, is disposed. The uppermost layer C is made thin by adjusting the color and texture as required.

(6) After heating the buffer / damping layer A, the shape-retaining layer B and the uppermost layer C at a temperature above the melting point of the melt fiber 1 and below the melting point of the regular fiber 2 as shown in FIG. 3 (b). The cooling press is placed between the upper and lower molds X and Y, and the layers A, B and C are pressed from the uppermost layer C side.

According to this embodiment, since the shape-maintaining layer B, which tends to have gloss when pressed, is hidden by the uppermost layer C containing a large amount of regular fibers 2, the appearance is matte. Therefore, compared to the first and second embodiments, the texture has a feeling of fiber.

Next, a fourth embodiment of the present invention will be described with reference to FIG. This carpet manufacturing method is
As a pre-step of the pressing step of (5) in the third embodiment, there is a step of needle punching (not shown) from the uppermost layer C side to the buffer / damping layer A as shown in FIG. 4 (b). . In FIG. 4, a broken line indicates a punching processing point. The other steps are the same as those in the third embodiment, and the description thereof will be omitted. According to this embodiment, the shape-retaining layer B can be made high in density and the shape-retaining effect can be enhanced.

The carpet manufactured by the manufacturing method of each of the embodiments described above has an apparent specific gravity of 0.1 g / cm ³ or less, and has an excellent cushioning effect against impact and the like.

Further, by using an optional mat made of vinyl chloride so as to be piled up on these carpets, the optional mat becomes a so-called weight layer and the vibration sound from the buffer / vibration damping layer A is further effective. Suppressed to
You can expect the soundproof effect.

【The invention's effect】

As described above, according to the carpet manufacturing method of the present invention, from the shape-retaining layer to the cushioning / damping layer,
Alternatively, the uppermost layer, the shape-retaining layer and the cushioning / vibration damping layer can be integrated in a very small number of steps. Further, when the uppermost layer is arranged on the upper surface of the shape-retaining layer, a natural fiber feeling can be created on the upper surface of the carpet, and the overall texture can be further improved.

In addition, by performing needle punching from the shape-maintaining layer to the buffer / damping layer, or from the uppermost layer to the buffer / damping layer, the density of the shape-maintaining layer is increased to improve the shape-maintaining effect. Since it can be improved and the thickness of the buffer / damping layer itself is hardly changed, the effect of buffer / damping is not reduced.

Therefore, the carpet according to the present invention is particularly useful mainly as a carpet for automobiles, and the cost reduction can be further promoted by saving labor of materials and processing steps.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view showing a first embodiment of a carpet manufacturing method.

FIG. 2 is a vertical sectional view showing a second embodiment of the carpet manufacturing method.

FIG. 3 is a vertical sectional view showing a third embodiment of the carpet manufacturing method.

FIG. 4 is a longitudinal sectional view showing a fourth embodiment of the carpet manufacturing method.

[Explanation of symbols]

 A cushioning / damping layer B shape retention layer C top layer 1 melt fiber 2 regular fiber

Claims (5)

[Claims] 1. A buffering / vibration layer in which melt fibers are mixed at a low rate with regular fibers, and a shape-retaining layer having a regularity after being cured by heat treatment and containing melt fibers at a high rate with regular fibers. A method for manufacturing a carpet, comprising a step of stacking and a step of cooling and pressing after heating each of the layers. 2. A step of stacking the shape-retaining layer on the buffer / damping layer, a step of interlacing fibers by needle-punching each layer, and heating the buffer / damping layer and shape-retaining layer. A method for producing a carpet, comprising a step of cooling and pressing afterwards. 3. A step of stacking the shape-retaining layer on the cushioning / damping layer, and a step of stacking an uppermost layer in which regular fibers and melt fibers are mixed at a low rate on the shape-retaining layer.
And a method for manufacturing a carpet, comprising the steps of heating each of the layers and then cold-pressing. 4. A step of stacking the shape-retaining layer on the buffering / damping layer, a step of stacking the uppermost layer on the shape-retaining layer, and needle-punching each layer to entangle the fibers. A method for producing a carpet, comprising: a step; and a step of cooling and pressing after heating each layer. 5. The regular fiber is synthetic fiber such as polyester and polypropylene, natural fiber such as cotton and wool, or anti-wool of each fiber, and the melt fiber is a polyester low melting point fiber, When the olefin low melting point fiber or the regular fiber is a natural fiber such as polyester fiber, cotton or wool, it is a polypropylene fiber or a polyethylene fiber having a lower melting point than that of the polypropylene fiber or the polyethylene fiber. Production method.