JPH11208346A - Floor carpet for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To partly impede fusing by hot air of a thermoplastic resin fiber mixed in a felt layer, set a shape holding property partly of the felt layer small as compared with the other part, even when a curved part of a floor-carpet receives tensile force at press molding time, restore a thickness partly of the felt layer. SOLUTION: A carpet layer 13 and a felt layer 12 layered in a reverse surface side of the carpet layer 13 to mix a thermoplastic resin fiber are heated, to be press molded along a shape of a floor panel, a floor carpet is formed. In either one of a surface or reverse side or both of the felt layer mixing the thermoplastic resin fiber, a film layer 15 interrupting hot air is arranged, a shape holding property of the felt layer 12 in a position arranging a film layer 15 is set small as compared with in the other part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor carpet for a vehicle and, more particularly, to a carpet layer on the front side and a felt layer laminated on the back side of the carpet layer, which are heated by a hot air circulation furnace. The present invention relates to a floor carpet for a vehicle which is formed by cold press forming along a shape of a floor panel of a vehicle.

[0002]

2. Description of the Related Art Conventionally, floor carpets have been mounted on floor panels, trunk rooms, luggage and the like of vehicles and the like. This floor carpet has a carpet layer for improving the feel and appearance on the surface side, a cushioning property and the like. In order to improve the cushioning property, the carpet layer is formed from a felt layer laminated on a part or the entire surface of the carpet layer, and the carpet layer and the felt layer are press-formed by a press mold corresponding to the shape of the floor panel.

[0003] A carpet layer and a felt layer are separately press-molded and then joined in a laminated state to form a floor carpet, and a thermoplastic resin for imparting shape retention as shown in FIG. The felt layer 2 in which fibers are mixed and the carpet layer 3 are laminated, and the raw material of the floor carpet 1 is heated by the hot air circulating furnace 5 and then the heated raw material of the floor carpet 1 is shaped into a predetermined floor panel. And a floor press carpet 1 having a desired shape in which the carpet layer 3 and the felt layer 2 are integrated with each other.

Further, the floor carpet 1 formed in a predetermined shape is moved to a primary trim type and a secondary trim type, and
A terminal treatment or a through hole having a desired shape is provided so that various members provided on the floor panel side of the vehicle can be pulled out above the floor carpet.

[0005]

However, when the carpet layer and the felt layer are separately press-molded and then laminated and joined to each other, the number of working steps is increased and the working efficiency is improved. Had the drawback that it could not be done.

Further, as shown in FIG. 3, when a similar convex portion 1A is formed on the floor carpet 1 corresponding to the central convex portion of the floor panel, the felt layer 2 mixed with thermoplastic resin fibers and the carpet are formed. When the layer 3 is disposed in the molding die and the lower die and the upper die are matched, the curved portions 1a and 1b of the floor carpet 1 are subjected to a tensile force and may be thinly formed. The curved portions 2a and 2b of the felt layer 2 of the floor carpet 1 formed thin under the tensile force may be kept in shape by cooling the thermoplastic resin fibers mixed in the felt layer 2. .

Further, since a power transmission mechanism and the like are disposed inside the central convex portion of the floor panel, there is a possibility that noise may enter the vehicle interior from the central convex portion of the floor panel. However, if the curved portions 2a and 2b of the felt layer 2 are formed thin and hard, there is a possibility that noise may enter from the thin and hard portion, and the felt layer 2 has sufficient sound absorption and sound insulation. Had the disadvantage that it could not be done.

An object of the present invention is to partially prevent the thermoplastic resin fibers mixed in the felt layer from being melted by hot air, and to compare the shape retention of a part of the felt layer with other parts. Even if the curved portion of the floor carpet receives a tensile force during press molding, it can restore a part of the felt layer thickness, preventing it from being molded thin and hard, An object of the present invention is to provide a floor carpet for a vehicle, which can improve sound absorption and sound insulation, and can improve work efficiency by uniform heating work, and is excellent in economic efficiency.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and a floor carpet for a vehicle according to claim 1 of the present invention has a carpet layer on a front surface side and a back surface of the carpet layer. In a vehicle floor carpet formed by heating a felt layer mixed with thermoplastic resin fibers laminated on the side and press-forming along the shape of the floor panel of the vehicle, the felt mixed with the thermoplastic resin fibers It is characterized in that a film layer that blocks hot air is disposed at a desired position in the layer, and the shape retention of the felt layer at the position where the film layer is disposed is reduced as compared with other portions.

[0010] In the floor carpet for a vehicle according to the second aspect of the present invention, the carpet layer on the front side and the felt layer mixed with the thermoplastic resin fibers laminated on the back side of the carpet layer are heated. In a vehicle floor carpet formed by press molding along the shape of the floor panel, a film layer that blocks hot air is provided on one or both of the front side and the back side of the felt layer in which the thermoplastic resin fibers are mixed. The felt layer is provided at a desired position, and the shape retention of the felt layer at the position where the film layer is provided is reduced as compared with other portions.

According to the floor carpet for a vehicle according to the first aspect of the present invention, since the film layer for blocking the hot air is disposed at the desired position on the felt layer in which the thermoplastic resin fibers are mixed, a uniform heating operation can be performed. Thus, the melting of the thermoplastic resin fibers in the felt layer at the position where the film layer is disposed can be reduced as compared with other portions, and the shape retention of the felt layer at the position where the film layer is disposed can be reduced. And the thickness can be restored even if the curved portion of the felt layer receives a tensile force during molding.

According to the floor carpet for a vehicle according to the second aspect of the present invention, it is desirable to provide a film layer that blocks hot air on one or both of the front side and the back side of the felt layer into which the thermoplastic resin fibers are mixed. Because it was arranged in the position where
The uniform heating operation can reduce the melting of the thermoplastic resin fibers of the felt layer at the position where the film layer is provided, and maintain the shape retention of the felt layer at the position where the film layer is provided at other parts. The thickness can be reduced, and the thickness can be restored even if the curved portion of the felt layer receives a tensile force during molding.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A floor carpet for a vehicle according to the present invention will be described below in detail with reference to the drawings. FIGS. 1 and 2 show an embodiment of a floor carpet for a vehicle according to the present invention, respectively. In this embodiment, a case where the present invention is applied to a floor carpet used for a floor panel will be described. The carpet includes a carpet used for a trunk room, a luggage, and the like, in addition to a carpet used for a floor panel.

As shown in FIGS. 1 and 2, the floor carpet 11 is formed of a carpet layer 13 on the front side and a felt layer 12 laminated on the back side of the carpet layer 13. The carpet layer 13 is formed of breathable PET fiber and PP fiber, and the felt layer 12 laminated on the back side of the carpet layer 13 is mixed with a thermoplastic resin fiber having shape retention. The carpet layer 13 may be formed by needling.

The felt layer 12 and the carpet layer 13 are joined by an adhesive such as polyester fleece, PE powder, or PP spunbond. As shown in FIG. 1, a protrusion 11A extending in the front-rear direction is formed at the center of the floor carpet 11. Therefore, the curved portion 11
a, 11b are formed, and the felt layer 12 is also provided with curved portions 12a, 12b at upper and lower positions.

The protrusion 11A of the floor carpet 11
On the felt layer 12 corresponding to the curved portions 11a and 11b at the upper and lower positions, a film layer 15 for blocking hot air is laminated. This film layer 15 is formed from a non-breathable polyester film, nylon film or the like.

In this embodiment, the felt layers 12 corresponding to the curved portions 11a and 11b at the upper and lower positions of the projecting portion 11A.
However, the film layer 15 can be disposed at a desired position. The sound insulation can be improved by the presence of the film layer 15.

As shown by arrows in FIG. 2, the flow of hot air 17 in the hot air circulating furnace is blocked by the air permeability of the felt layer 12 at the position where the film layer 15 is provided.
Is heated by the hot air 17 of the hot air circulating furnace, the hot air 1 is applied to the felt layer 12 where the film layer 15 is provided.
7 can be prevented from hitting.

By blocking the hot air 17 by the film layer 15, it is possible to prevent the thermoplastic resin fibers having a shape retaining property mixed in the felt layer 12 from being melted. The shape retention of the felt layer 12 at the position where it is provided can be reduced as compared with other portions.

The film layer 15 is not limited to the one provided between the felt layer 12 and the carpet layer 13 as shown in FIGS. 1 and 2, respectively.
2 may be provided on the back side, and in this case, it is preferable to supply the hot air 17 from the back side of the felt layer 12 of the floor carpet 11.

Further, a film layer 15 may be provided on the front surface and the back surface of the felt layer 12, and the felt layer 12 may be sandwiched therebetween. In this case, the felt layer 12
And the hot air 17 can be further blocked. In addition, although the hot air 17 of the hot air circulation furnace was used as the heating means, the invention is not limited to this, and various heating means can be used.

[0022]

The above is the embodiment of the floor carpet for a vehicle according to the present invention. According to the floor carpet for a vehicle according to the first aspect of the present invention, the felt layer mixed with the thermoplastic resin fiber is used. Since the film layer that blocks the hot air is arranged at a desired position, the melting of the thermoplastic resin fibers of the felt layer at the position where the film layer is arranged is reduced by uniform heating work as compared with other parts. The shape retention of the felt layer at the position where the film layer is disposed can be made smaller than that of other parts, and even if the curved portion of the felt layer receives a tensile force during molding, the thickness can be reduced. Can be restored.

According to the floor carpet for a vehicle according to the second aspect of the present invention, it is desirable that a film layer that blocks hot air is provided on one or both of the front side and the back side of the felt layer into which the thermoplastic resin fibers are mixed. Because it was arranged in the position where
The uniform heating operation can reduce the melting of the thermoplastic resin fibers of the felt layer at the position where the film layer is provided, and maintain the shape retention of the felt layer at the position where the film layer is provided at other parts. The thickness can be reduced, and the thickness can be restored even if the curved portion of the felt layer receives a tensile force during molding.

According to the present invention, the film layer can partially prevent the thermoplastic resin fiber mixed in the felt layer from being melted by hot air, and the shape retention of a part of the felt layer can be reduced by another part. It is possible to restore a part of the thickness of the felt layer even if the curved portion of the floor carpet receives tensile force during press molding,
A vehicle that is flexible and excellent in sound absorption with no fear of being formed thin and hard, can improve sound insulation by the film layer, and can improve work efficiency by uniform heating work. Floor carpet can be obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view of a floor carpet for a vehicle according to the present invention.

FIG. 2 is a cross-sectional view showing a heated state of a raw material of the vehicle floor carpet according to the present invention.

FIG. 3 is a sectional view of a conventional floor carpet for a vehicle.

FIG. 4 is a cross-sectional view showing a heated state of a raw material of a conventional floor carpet for a vehicle.

[Explanation of symbols]

 Reference Signs List 11 floor carpet 11A projecting part 11a curved part 11b curved part 12 felt layer 12a curved part 12b curved part 13 carpet layer 15 film layer 17 hot air

Claims (2)

[Claims] 1. A carpet layer on the front side and a felt layer mixed with thermoplastic resin fibers laminated on the back side of the carpet layer are heated and press-formed along the shape of a floor panel of a vehicle. In a floor carpet for a vehicle, a film layer that blocks hot air is disposed at a desired position on the felt layer in which the thermoplastic resin fiber is mixed, and the shape retention of the felt layer at the position where the film layer is disposed is improved. A floor carpet for a vehicle, characterized in that it is smaller than other parts. 2. A carpet layer on the front side and a felt layer mixed with thermoplastic resin fibers laminated on the back side of the carpet layer are heated and press-formed along the shape of the floor panel of the vehicle. In the floor carpet for a vehicle, a film layer that blocks hot air is disposed at a desired position on one or both of the front side and the back side of the felt layer mixed with the thermoplastic resin fiber, and the film layer is formed. A floor carpet for a vehicle, wherein the shape retention of a felt layer at a position where the felt layer is disposed is reduced as compared with other portions.