JPH11198223A - Method and apparatus for molding fiber cushioning layer of flooring material for automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate the generation of end materials by cutting and to use materials efficiently by press-molding in a state in which after a blank at molten fibers of a low melting point being placed at a prescribed position of a lower molding mold, indentation plates attached to a molding mold part are moved to the outside position of a product, and the blank is pushed. SOLUTION: To weld a part of low melting point binder fibers slightly, hot air of a temperature between the melting point and the decomposition point of the fibers is made to penetrate forcibly. A blank of the molten fibers which was treated at the temperature is placed at a prescribed position of a lower mold, and when one of front and rear fringe parts and one of right and left fringe parts form standing walls to be blank receivers, to the residual fringe parts, indentation plates 21, 22, 23, 214 connected with cylinders 211, 212, 221, 222, 241, 242 are moved in the push direction until a molding is formed. Subsequently, an upper mold which contacts the indentation plates and other standing walls is brought down to press-mold the blank.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for forming a fiber cushion layer of an automobile floor laying material.

[0002]

2. Description of the Related Art A thin fiber layer is formed by using a card machine from a fiber obtained by blending a high-melting fiber and / or a non-melting fiber with a low-melting binder fiber, and then laminated into a bulky web, or a mixed fiber is formed by a cylinder opening machine, a garnet, and the like. Laminating through a fiber opening machine to form a bulky fiber layer, hot air penetration is performed by far-infrared treatment to partially melt the low melting point fiber to form a bulky fiber layer that can be carried, and cut into a predetermined size to obtain a hot air blank. Penetration furnace is heated by hot plate contact heating to melt the low melting point binder fiber, immediately set between the molds and press molded,
Thereafter, the outer periphery is cut to form a fiber cushion layer of an automobile floor laying material.

[0003]

Since the outer periphery is cut after molding, a cut off material is generated. Since the low melting point binder fiber is melted and the other fiber is welded to this cut material, It cannot be returned to short fibers with a hair-removing machine, which is one of the environmental problems for incineration or landfill. Therefore, an object of the present invention is to provide an automobile floor laying fiber cushion layer without generating cut off material.

[0004]

According to the present invention, there is provided a method for forming a fiber cushion layer of a floor laying material for automobiles comprising a mixed fiber layer of a high melting point fiber and / or a non-melting fiber and a low melting point binder fiber. The mixed fiber layer is made into a bulky fiber layer that is lightly fused in advance, and a blank larger than the size of the molded product is passed through hot air at a temperature between the melting point of the low-melting fiber and the melting point of the high-melting fiber and below the decomposition temperature of the non-melting fiber. Through the heat furnace, place it in the mold lower mold predetermined position, and immediately push the blank to the outer edge position of the molded fiber cushion layer with at least one press plate of cylinder connection on each of the front and rear and right and left edges of the blank mold lower mold. , Car floor laying characterized by lowering and pressing an upper die inscribed in the push-in plate and other standing walls Method. "By molding method molding of fiber cushion layer.

[0005] The molding apparatus used for this purpose is described as follows: "A device for applying a fiber cushion layer to a floor laying material for automobiles is connected to at least one cylinder at each of the front and rear and left and right edges of a lower mold blank forming portion. A floor laying material for automobiles, comprising a push plate, wherein the push plate can push and move the blank to the outer edge position of the fiber cushion molded product, and the upper die inscribes the push plate and the remaining fixed upright wall at the end position of the movement. The problem could be solved by using the "fiber cushion layer forming apparatus."

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The high melting point fiber is, for example, polyester, nylon, acrylic, polypropylene fiber or the like. Polyester fiber is the most desirable high melting point fiber in consideration of light deterioration resistance, heat resistance, cushioning property, cost and the like. Non-molten fibers have no melting point and have the property of decomposing when the temperature rises, and examples thereof include cotton, hemp, wool, and glass fibers.

The low melting point binder fiber is a fiber having a melting point lower by at least 20 ° C. than the melting point of the high melting point fiber. When the high melting point fiber is a polyester fiber, terephthalic acid is used as an acid component.
Isophthalic acid, adipic acid, sebacic acid, etc., ethylene glycol, butylene glycol,
Co-condensed polyesters such as isobutylene glycol are preferred. The low-melting fiber is composed of a single polymer, and in addition to a composite fiber whose core is made of a high-melting polymer and whose sheath is made of a low-melting polymer, or of various ratios of a high-melting polymer and a low-melting polymer. Also includes side-by-side fibers. These high-melting fibers and low-melting fibers may be irregular cross-sections or hollow fibers irrespective of their cross-sectional shapes.

The formation of the bulky fiber layer composed of the high-melting fiber and the low-melting fiber is carried out by a conventional carding machine, lamination by layers or cylinder opening, garnet opening, layer lamination, etc., and a bulky fiber layer having a thickness of about 50 mm. About 1000 g / m ²
Although it is manufactured to a certain degree, it is better to pass through a card machine in terms of uniformity. The bulky fiber layer does not need to be a single layer, but may be a multiple layer, particularly a lower layer having two layers having different fiber ratios and fiber diameters for cushioning and heat insulation from the floor.

[0009] Far-infrared heating is also used to facilitate subsequent handling, but since the low-melting binder fiber is partially lightly welded, the melting point is higher than the melting point of the low-melting binder fiber and lower than the melting point of the high-melting fiber, and is lower than the decomposition temperature of the non-melting fiber. It is preferable to force hot air having a temperature of The molded product was cut into dimensions necessary for a blank.

A blank which has been treated at the above temperature to melt the low-melting fiber is placed at a predetermined position on the lower mold, and one of the front and rear edges and one of the right and left edges of the mold are used as the blank receiving wall. When forming, the press plate quickly connected to the cylinder at the remaining edge is moved in the blank pressing direction until the molded product external dimensions are reached, and then the press plate and other standing walls, if any, are also inscribed on the standing walls. The mold is lowered to press-mold the blank.

As a result, it is possible to eliminate the generation of cut off pieces without the need to cut the outer periphery of the molded product. Each indentation plate is shaped to form the outer shape of the molding. The surface of the lower mold has an uneven shape so as to be counter-fitted to the shape of the floor of the car, and the blank molding part has a front and rear cushion fiber layer in one mold, or an integrated front and rear. It is most preferable that the entire cushion layer for one vehicle can be molded by one pressing of the molding device, but when the front and the rear or those are divided,
The present invention includes a case where a mold corresponding to each shape is used.

[0012]

EXAMPLE 1 40% polyester fiber having a length of 13 denier 51 mm, 30% polyethylene terephthalate fiber having a denier of 51 mm, melting point 110 of 51 mm 2 denier
A polyester co-condensate having a low melting point of 2 ° C. and a core portion forming polyethylene terephthalate in a sheath portion is blended with 30% of a polyester binder composite fiber of 51 mm having a denier of 51 mm to form a laminated web through a cylinder opening machine, a card machine, and a layer device. Was subjected to hot air penetration treatment for 30 seconds, and was lightly welded to a thickness of about 40 mm and 1000 g / m ² .

From now on, it is cut into 1500 mm: 700 mm to form a blank for the cushion fiber layer at the front part.
The blank was cut into 300 mm * 600 mm to form a cushion fiber layer blank at the rear. After placing both blanks in a hot-air forced-penetration furnace and passing hot air at a temperature of 170 ° C. for 40 seconds, each of them is placed in a predetermined mold, that is, a front blank is placed in a front mold part (2) and a rear blank is placed in a rear mold part (3); Immediately, the front blanks are provided with cylinders (211, 212, 221, 222, 2
31, 232, 241, 242) The front and rear and left and right push plates are moved inward to the product shape position by the push plates (21, 22, 23, 24) having the outer shape of the product and stopped, and at the same time, the rear blank is also the same. The push plate (31, 33, 34) is stopped to move to the outer shape position of the product, but the rear edge has a vertical wall (32) at the rear and receives a blank, so that the push plate (31, 33, 34) is received.
34) are provided at the other three edges. The upper die inscribed in the plates (21, 22, 23, 24, 31, 33, 34) and the standing wall (34) was lowered and pressed to form a fiber cushion layer. A fiber cushion layer having a good fit property on the floor of an automobile was obtained without cutting the outer periphery.

[0014]

According to the present invention, a blank having a size slightly larger than a product obtained by melting the low melting point fiber is placed at a predetermined position in the lower mold, and is provided on at least one of the front, rear, left and right edges of the mold. Since the press plate is moved to the outer shape of the product and pressed into the product as it is while the blank is pressed in, the process of cutting the outer periphery of the molded product can be omitted, and the material is effectively used without the generation of scraps due to cutting. We were able to.

[Brief description of the drawings]

FIG. 1 is a plan view of a lower molding die.

FIG. 2 is a sectional view taken along the line AA ′ in FIG. 1;

FIG. 3 is a sectional view taken along the line BB ′ of FIG. 1;

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Lower mold 11 Lower mold surface 2 Front part 21 Front front edge pressing plate 211, 212 Cylinder of front front edge pressing plate 22 Front rear edge pressing plate 221, 222 Cylinder of front rear edge pressing plate 23 Front left edge Part push plate 231, 232 Cylinder of front left edge push plate 24 Front right edge push plate 241, 242 Cylinder of front right edge push plate 3 Rear part 31 Rear front edge push plate 311, 312 Rear front edge push plate Plate cylinder 32 Rear trailing edge standing wall 33 Rear left edge pushing plate 331, 332 Rear left edge pushing plate cylinder 34 Rear right edge pushing plate 341, 342 Rear right edge pushing press Cylinder 4 blank

Claims (2)

[Claims] 1. A bulky fiber layer in which a mixed fiber layer is lightly fused in advance in forming a fiber cushion layer of a floor laying material for automobiles comprising a mixed fiber layer of a high melting point fiber and / or a non-melting fiber and a low melting point binder fiber. The blank having a size larger than the size of the molded product is passed through a heating furnace through which hot air having a temperature equal to or higher than the melting point of the low-melting fiber and equal to or lower than the melting point of the high-melting fiber and equal to or lower than the decomposition temperature of the non-melting fiber is passed. Immediately, at least one push plate of cylinder connection is pushed to the outer edge position of the molded fiber cushion layer on each of the front and rear and right and left edges of the blank forming lower die, and the upper die is inscribed in the push plate and other standing walls. Forming a fiber cushion layer of an automobile floor laying material by lowering and pressing. 2. An apparatus applied to form a fiber cushion layer of a floor laying material for an automobile has a press plate connected to at least one cylinder at each of front and rear and right and left edges of a blank forming portion of a lower die. An apparatus for forming a fiber cushion layer of a floor laying material for automobiles, wherein the plate is capable of moving the blank by pushing the blank to the outer edge position of the fiber cushion molded article, and the upper die is inscribed in the pushing plate and the remaining fixed upright wall at the movement end position. .