JPS597152Y2 - Composite mat for automobiles - Google Patents

Description

[Detailed explanation of the idea] This invention relates to a composite mat for automobiles.

Carpets, sound-insulating mats, and felt are layered together as mats laid on car floors to provide soundproofing, vibration-proofing,
It not only improves insulation, but also improves stepping comfort and appearance.

Conventional mats are made by cutting each of the above-mentioned materials to the desired size, then compressing or vacuum molding each material to follow the unevenness of the car floor, and then molding each material into a shape. Since these materials are used by simply stacking them on top of each other, it is necessary to process each material into a hollow shape, and there is also the problem that the materials may shift from each other during use.

It is conceivable to integrally laminate the above-mentioned mold materials with an adhesive, but this has the drawbacks that the organic solvent of the adhesive worsens the working environment, the organic solvent remains even after processing, and the number of work steps increases. be.

This invention eliminates the drawbacks of the above-mentioned conventional automobile mats and provides a composite automobile mat made of a laminate or molded product in which the above-mentioned materials are simultaneously and integrally bonded.

An embodiment of this invention will be described below with reference to FIGS. 1 to 4.

Fig. 1 shows a carpet material C forming the upper layer of the composite mat, which is composed of a raised part 1 and a base material 2 that supports the base of the raised part 1, and the lower surface of the base material 2 is coated with polyethylene. The thin layer 3 is fused as a packing.

This carpet material C has a raised part 1 in a loop shape or a cut shape, and has a basis weight of 500 to 1500 g.
/m' and a thickness of 5 to 15 mm are preferable.

The yarn forming the raised part 1 of the carpet material C is made of nylon, polypropylene, rayon, or a mixture thereof, and the base material 2 is made of hemp, nylon,
It is made of polypropylene, polyethylene, and rayon.

The above-mentioned carpet material C includes a needle-punched carpet obtained by punching a web made of filament yarns, and in this case, the base material 2 is often omitted.

The polyethylene thin layer 3 provided on the back surface of the carpet material C is made of fused polyethylene, and the polyethylene slightly penetrates into the weave of the base material 2, and its amount is 200 to 500 g/m'. preferable.

FIG. 2 shows a sound insulating mat material M forming the middle layer of the composite mat, which includes a sound insulating mat 4 and a thin nonwoven fabric layer 5 provided on its upper surface as a medium layer.

The sound insulation mat 4 has a specific gravity of 0.5 to 3.0 and a thickness of 0.5 to 6.
mm of polyvinyl chloride sheet, and in order to increase the above specific gravity, powder with a high specific gravity such as lead oxide, iron oxide, calcium carbonate, etc. is mixed with the polyvinyl chloride as a filler, and then the filler is heated. It is formed from a resin composition containing plasticizers, stabilizers, blowing agents, pigments, etc.

This sound insulating mat 4 has the function of absorbing and reflecting engine noise.

A thin nonwoven fabric layer 5 that is pressure-fused to the top surface of this sound insulation mat 4
It is preferable that the fiber be made of a composite fiber, but it may be made of other fibers.

This nonwoven fabric thin layer 5 serves as a medium for press-bonding the sound insulating mat material M with the polyethylene thin layer 3 on the lower surface of the carpet material C when forming a composite mat.

The thickness of the nonwoven fabric thin layer 5 is 2 mm or less, and the thickness is 2 mm.
If the value exceeds 100, when the thin nonwoven fabric layer 5 on the top surface of the sound insulation mat material M and the thin polyethylene layer 3 of the carpet material C are overlapped and heated from the sound insulation mat 4 side, heat conduction to the thin polyethylene layer 3 will be insufficient and crimping will occur. If the heating temperature is not properly measured or the heating temperature is set too high, the carpet material C may be damaged.

Of course, instead of the non-woven thin layer described above, a fibrous sheet such as woven fabric or paper may be used as the medium layer.

FIG. 3 shows felt F forming the lower layer of the composite mat.

The above felt is a commonly used felt with a thickness of 5 to 30 mm and a weight of 350 to 1800 g/m.
and is appropriately set depending on the desired degree of sound insulation, vibration isolation, and sound absorption.

Natural fibers, synthetic fibers, and inorganic fibers are used as materials for forming the felt F, and these fibers are bonded together into a felt shape using an adhesive or twenty dollar punching.

This felt F functions as a heat insulator, a vibration absorber, and a sound absorber.

Of the felts F mentioned above, felts bonded with adhesive are preferred because they are easy to process into molds and are less susceptible to deformation after molding.

In the embodiment described above, instead of a fibrous sheet such as a non-woven thin layer on the top surface of the sound-insulating mat material M, a thickness of 2 m
It is also possible to fuse an ethylene/vinyl acetate copolymer layer of less than m to form a medium layer, and then bond this ethylene/vinyl acetate copolymer layer to the polyethylene thin layer 3 on the lower surface of the carpet material C.

In addition, when an ethylene/vinyl acetate copolymer layer is provided as a medium layer on the upper surface of the sound insulation mat material M, a rubber latex liquid is applied and dried rubber latex layer instead of the polyethylene thin layer on the lower surface of the carpet material C. may also be packed, in this case the date amount is 150 to 1000
FIG. 4 shows a composite mat in which the carpet material C, the sound-insulating mat material M and the fuel }F are sequentially stacked and integrally molded at the same time.

The optimal method for manufacturing a composite mat using each of the materials explained above is to overlap the top surface of the sound insulation mat material M on the bottom surface of the carpet material C and heat the sound insulation mat 4 to 150 to 200°C using a heater. , heat for 20-60 seconds,
Next, the heated two-layer material is introduced into a mold having concave and convex portions, and a ferret F is superimposed on the lower surface of the sound insulating mat material M, and a mold having a concavo-convex shape is inserted from the ferret F side by 0.2~
Pressurized at a pressure of 10 kg/c [II2, preferably 80
The materials are held at a temperature of 1 to 3 minutes below DEG C to press them together and at the same time form a composite mat having irregularities.

Note that, instead of the press-bonding method, a vacuum mold method, a blow mold method, or the like can be used for the above-mentioned mold.

As explained above, this invention consists of a carpet material having a packing of a thin layer of polyethylene or a rubber latex layer on the lower surface, and a thin layer of fiber sheet or ethylene/vinyl acetate with a thickness of 2 mm or less bonded to the lower surface of the carpet material on the upper surface. A sound insulating mat material having a medium layer of a copolymer layer and mainly made of polyvinyl chloride, and having a thickness of 5 to 30 mm and a basis weight of 350 to 1, bonded to the lower surface of the sound insulating mat.
Because it is a composite mat made by overlapping 800 g/m" felt and molding it simultaneously, each material will not shift or lose its shape when used on the floor of a car. Furthermore, it has less shrinkage than certain types of products with one layer.

Furthermore, since the three materials mentioned above are molded simultaneously and integrally, manufacturing is simple and the number of man-hours is reduced.

Furthermore, since no adhesive is used to join the materials, problems such as deterioration of the working environment caused by organic solvents in adhesives and drawbacks caused by residual organic solvents in the product are eliminated.

[Brief explanation of the drawing]

Fig. 1 is a vertical cross-sectional view of the carpet material according to the embodiment of this invention, Fig. 2 is a vertical cross-sectional view of the sound-insulating mat material, Fig. 3 is a vertical cross-sectional view of the felt, and Fig. 4 is a vertical cross-sectional view of the molded composite mat. FIG. C: carpet material, M: sound insulation mat material, F: felt, 3: polyethylene thin layer (packing), 4: sound insulation mat, 5: nonwoven fabric thin layer (media layer).

Claims (3)

[Scope of utility model registration request] (1) A carpet material having a packing of a thin polyethylene layer or a rubber latex layer on the lower surface, and a medium layer of a thin fiber sheet layer or an ethylene-vinyl acetate copolymer layer with a thickness of 2 mm or less bonded to the lower surface of the carpet material on the upper surface. and a sound insulation mat material mainly made of polyvinyl chloride, and a thickness of 5 to 30 mm bonded to the lower surface of the sound insulation mat.
A composite mat for an automobile, characterized in that it is made by overlapping felt with a weight of 350 to 1800 g/m2 and integrally press-bonding or molding them at the same time. (2) The packing on the lower surface of the carpet material is a polyethylene thin layer, and the medium layer on the upper surface of the sound insulation mat is a thin fiber sheet layer with a thickness of 2 mm or less or an ethylene-vinyl acetate copolymer layer. ) Composite mat for automobiles as described in item 2. (3) The automobile according to claim 1, wherein the packing on the lower surface of the carpet material is a rubber latex layer, and the medium layer on the upper surface of the sound insulation mat is an ethylene-vinyl acetate copolymer layer with a thickness of 2 mm or less. composite mat.