JPH1035341A - Molding method of carpet under member for car - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the floating of a carpet under member with a simple structure, and to improve the quality of the same. SOLUTION: This molding method heats the nonwoven raw fabric of proper size, and compresses and molds the same into a shape having a concave and convex part 12a corresponding to a car body panel by a mold 2. On this occasion, plural slits 1a are formed in the thickness direction of the raw fabric on a rear face side of the nonwoven fabric 1 corresponding to the concave and convex part of the panel. Thereby, the nonwoven fabric 1 is formed into the concave and convex part 12a of acute angle through the slits 1a in the compression molding process by the mold 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a carpet under material for a vehicle, which is a backing layer of a carpet laid in a cabin or a trunk.

[0002]

2. Description of the Related Art A conventional carpet structure for a vehicle is formed as a three-dimensional single piece according to the shape of a panel on the floor side, and, for example, a carpet under material (hereinafter, referred to as a nonwoven fabric) as a backing layer on a skin layer. By providing the under material, the skin layer mainly gives appearance characteristics, and the under material gives soundproofing performance, rigidity or holding performance. In addition, the panels in the cabin or trunk in which carpets are laid are rarely flat, and generally have large and small irregularities. The flatness and soundproof performance are impaired. The adhesion to the panel is solely dependent on the formability of the under material that is in direct contact. The under material is roughly classified into a urethane foam-based material and a non-woven fabric-based material obtained by compression-molding a fiber. For a vehicle, the non-woven fabric is often used because of its excellent soundproofing performance and the like.

FIG. 3 schematically shows a conventional molding method using a nonwoven fabric as an under material. The nonwoven fabric web 1 shown in FIG.
A fiber blend containing about 95% by weight and about 5 to 30% by weight of a low melting point (110 ° C.) polyester fiber. The thermoplastic polyester fiber having a low melting point is heated and melted during molding to function as a binder together with moldability. I do. Then, the nonwoven fabric web 1 is cut into a blank size designed according to the product, and after being heated to about 200 ° C. by a heating means such as a hot blast stove, is set in a molding die 2, The upper and lower dies 3, 4 are press-formed while being compressed and shaped. The molding surface of the lower die 4 is provided with concave portions 4a and 4b corresponding to the concave portions on the panel side. Therefore, the formed under material 10 has protrusions 11a and 11b corresponding to the recesses 4a and 4b.

[0004]

In the above-described method of forming a carpet under material, in a mode in which the recesses 4a and 4b provided in the lower mold 4 are relatively shallow,
In the process of compression molding of the nonwoven fabric web 1, it is filled or embedded in the recess and shaped as designed. However, a dent such as a concave portion formed on the molding surface has a diameter of 20 mm.
In such a deep mode, it is difficult to completely fill the concave portion with the nonwoven fabric web 1 even by compression molding as shown in FIG. 3B, and the protrusion of the under material 10 formed as an enlarged portion in FIG. A portion where the portion 11a does not contact the bottom surface of the concave portion 4a;
The so-called floating can cause roundness or partial chipping. The occurrence of the lifting depends on the fiber material of the raw nonwoven fabric and the degree of compression.
This tends to occur when the shape of 0 is a flat front surface 10a and a relatively deep and convex portion having a sharp rise is formed on the rear surface 10b. Then, such a floating impairs the adhesion to the panel surface, making it impossible to maintain the flatness in a used state, and causes the surface to be wavy or the like, thus causing a deterioration in appearance.

An object of the present invention is to solve the above-mentioned problem, and an object of the present invention is to provide a method of forming an under material capable of easily achieving a high quality by eliminating the occurrence of floating easily. Other objects will be clarified with the following description.

[0006]

That is, in the method of forming a carpet under material for a vehicle according to the present invention, a nonwoven fabric material cut into a predetermined large size is heated, and a concave and convex portion corresponding to a vehicle body panel is formed by a molding die. In the method for molding a carpet undermaterial for a vehicle to be compression-molded into a shape having a shape, by providing a plurality of slits in the thickness direction of the raw fabric at a rear side portion of the nonwoven fabric corresponding to the uneven portion of the panel. The raw nonwoven fabric is formed in the shape of an acute concave and convex portion through the slit during the compression molding process by the molding die.

[0007] The above-mentioned orientation of the present invention is to solve the problem of floating caused by the conventional method, by providing a slit at the most compressively deformed portion of the nonwoven fabric regardless of the fiber material composition of the nonwoven fabric. Due to the physical action of the slit, the corresponding portion of the nonwoven fabric is easily filled or deformed or compressed and filled in the concave portion. Therefore, in the present invention,
The fiber material of the nonwoven fabric raw material is not limited to the polyester fiber, and for example, synthetic fibers such as polystyrene and nylon, natural fibers such as wool and hemp, and recycled fibers thereof can be used. Also, the basis weight, fiber diameter and length of the fiber material are not particularly limited as long as they are in a normal mode.

Further, it is a prerequisite that the carpet under material is heated by heating a nonwoven fabric web and compression-molded by a molding die into a shape having irregularities corresponding to the vehicle body panel. In this case, the carpet under material alone is formed, and the fibrous material or the like serving as a skin layer is attached to the upper surface of the nonwoven fabric raw material, and the skin layer is integrated simultaneously with the molding of the carpet under material. May be obtained,
The present invention may be any.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows main steps of a method for forming a carpet undermaterial for a vehicle according to the present invention.
Shows the state before the mold clamping, and FIG. 2B shows the state after the mold clamping. In addition,
The molding method shown in FIG. 1 is different from the conventional method in that a slit is previously formed in the nonwoven fabric. Since the molding die used is the same, the same parts as those in FIG. 3 are denoted by the same reference numerals. . The method for forming a carpet undermaterial for vehicles of the present invention comprises a slit forming step of forming a slit 1 a in the nonwoven fabric web 1, a heating process of heating the nonwoven fabric web 1, and a compression process of compression-molding with a molding die 2. Has become.
Hereinafter, each step will be described in detail.

The raw woven fabric 1 used is a fiber blend containing about 80% by weight of a polyester fiber having a high melting point and about 20% by weight of a polyester fiber having a low melting point (melting point of about 110 ° C.). This is the same as the conventional one in that the thermoplastic polyester fiber having a melting point is heated and melted during molding to function as a binder together with moldability, and is cut into a blank size designed according to the product. However, this nonwoven fabric web 1 has a plurality of slits 1 before being sent to the heating step.
The difference is that a is formed. In addition, nonwoven fabric raw material 1
Has a thickness T1 of about 40 mm.

The slits 1a are formed corresponding to the concave and convex portions of a panel such as a vehicle body floor, which is an installation surface.
That is, the molding surface of the lower mold 4 corresponds to the shape of the panel, and the concave portion 4a is provided at a position corresponding to the concave portion of the panel. The depth of the recess 4a is about 20 mm, and the bottom surface and the side surface are at right angles. And the slit 1
Reference numerals a and 1a are located on the back surface side of the nonwoven fabric web 1 corresponding to the concave portions 4a, and are formed at substantially the same interval as the opening width of the concave portions 4a as shown in FIG. In this case, the slit width is preferably set to 2 to 5 mm. The depth T2 of the slit 1a is equal to the thickness T1 of the nonwoven fabric web 1.
In general, the thickness is preferably suppressed to about １ ／ or less of the thickness T1 of the raw nonwoven fabric 1, although it varies depending on the compression ratio, the size and the depth of the concave portion 4a, and the like. This is because if the slit 1a is formed to a depth greater than that, the slit may remain even after molding.

In the heating step, the nonwoven fabric sheet 1 with the slit is set in a hot blast stove, and is heated at about 200 ° C. for about 30 minutes.
Heat for ~ 60 seconds. Thereafter, it is set on the molding surface of the lower mold 4 and pressed and formed by compression while being clamped by the upper and lower molds 3 and 4 to form a shape. These steps are performed in a conventional manner.

FIG. 1B shows a state in which mold clamping has been completed. The under material 10, which is a molded product, is compression molded into a shape corresponding to the molding surface, and the thickness t1 of the general portion (flat portion) excluding the convex portion 12a corresponding to the concave portion 4a is about 10 mm. I have. And the convex part 12a which becomes a problem
Fills the inside of the concave portion 4a and has a sharp convex shape as designed or equivalent to the concave portion 4a. Such a sharp convex shape is notably different from that obtained by compression molding without a slit as in the related art, and is extremely effective in preventing a portion that does not hit the bottom surface of the conventional concave portion 4a, that is, in preventing so-called floating. It turned out to be effective.

FIG. 2 shows a variant of the method according to the invention in a manner similar to FIG. In this modified example, only the configuration in which the magic fastener member 15 is provided in the concave portion 4a of the lower die 4 is different from the molding method of FIG. Therefore,
Since what has been described with reference to FIG. 1 also applies to this modification as it is, only the magic fastener member 15 will be described below in detail.

The magic fastener member 15 is capable of adsorbing the nonwoven fabric material 1 to be formed in the compression process,
It is stuck over the bottom surface and side surface forming a. In the compression molding process by the molding die 2, the nonwoven fabric web 1, in particular, the web portion between the slits 1 a, 1 a is compressed and deformed into the recess 4 a while being compressed. As a result of being easily drawn into the concave portion 4a also by the suction action, a more accurate acute convex shape is formed. The portion where the magic fastener member 15 is provided corresponds to the portion where the floating is likely to occur as shown in the enlarged portion of FIG. 3B, and this portion is exclusively sucked to the molding surface side. Also, after compression molding, the fiber material constituting the raw nonwoven fabric 1 is bonded with the binder, so that the suction with the magic fastener member 15 is almost released, and no trouble occurs when the molded product is released from the mold. . Thus, the molding method of the present invention can be variously modified or developed within a range satisfying the requirements described in claim 1.

[0016]

As described above, the method for forming a carpet undermaterial for a vehicle according to the present invention has the following effects. By simply forming a slit in the nonwoven fabric web, even if the unevenness of the molded under material is large, it will always be formed in the shape of the mold or the concave and convex shape as designed, and the occurrence of floating as in the past with the minimum man-hour It can be reliably eliminated. As a result, in the specification where the panel that is the laying surface has large irregularities, it is not necessary to consider the occurrence of floating when deciding the fiber material composition and the degree of compression of the nonwoven fabric raw material. Can be expanded. In addition, since the conventional carpet cannot be lifted, the carpet using the molded under material has improved adhesion to the panel on which the carpet is laid. Therefore, the surface is less likely to undulate during use, and the appearance and sound absorption can be improved.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing main steps of a method for molding a carpet undermaterial according to the present invention.

FIG. 2 is a schematic cross-sectional view showing a modified example of the present invention in a mode similar to FIG.

FIG. 3 is a schematic cross-sectional view showing main steps of a conventional method for forming a carpet under material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Nonwoven fabric raw material 1a Slit 2 Mold 3 Upper die 4 Lower die 4a Depression 10 Carpet under material 12a Convex part T1 Thickness of raw nonwoven fabric T2 Depth of slit t1 Thickness of flat portion of carpet under material

Claims (1)

[Claims] 1. A method for forming a carpet under material for a vehicle, comprising heating a nonwoven fabric sheet cut to a predetermined size and compression-molding the nonwoven fabric into a shape having irregularities corresponding to a vehicle body panel by a molding die. By providing a plurality of slits in the thickness direction of the raw fabric in the back side portion of the raw nonwoven fabric in correspondence with the uneven portion, the raw nonwoven fabric passes through the slits in the compression molding process by the molding die. A method for forming a carpet under material for a vehicle, wherein the carpet under material is formed in a sharp concave and convex shape.