JPS63270129A - Manufacture of floor carpet for vehicle - Google Patents

Abstract

PURPOSE:To obtain a floor carpet for vehicle which is superior in adhesion between the floor carpet and an asphalt layer, vibration damping effect, noise reduction effect and feeling and is rich in economical merits, by a method wherein press molding of a buffer layer composed of a buffer material and a carpet layer composed of a carpet material is performed under an integrally laminated state. CONSTITUTION:An asphalt composition 18 formed by composing mainly of asphalt and compounding a lubricant or a filling agent appropriately is heated and molten, cast into a recessed part of an uneven pat 15 of a bottom force 12 and an asphalt layer 20 wherein a protrusion 19 corresponding to the recessed part is formed is molded. The asphalt layer 20 is cooled and a buffer material 22 such as a felt material is arranged on the upper part of the same. A backing layer 26 of a carpet material 24 is arranged on the upper part of the buffer material 22 under a heated state. A floor carpet 27 of a desired form is formed under a state where the bottom force 12 and a top force 13 are registered, press molding is performed and the backing layer 26 and the buffer material 22 are joined to each other.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for manufacturing a floor carpet for a vehicle, and more specifically, the present invention relates to a method for manufacturing a floor carpet for a vehicle. The present invention relates to a method of manufacturing a vehicle floor carpet comprising a carpet layer and a cushioning layer that are press-molded along the length of the carpet.

[Conventional technology]

Conventionally, floor carpets have been installed on the floors of vehicles, etc., and these floor carpets consist of a carpet layer to improve the feel and appearance of the surface side, and a buffer layer to improve cushioning and cushioning properties. formed,
These carpet layers and buffer layers are press-molded to correspond to the shape of the floor.

The carpet layer and the buffer layer are press-molded separately and then joined into a laminated state.The carpet layer is molded, the carpet layer is placed in a foam mold, and the buffer layer is placed on the back side of the carpet layer. There is one in which a foamed synthetic resin stock solution is injected to form a buffer layer.

Furthermore, for the purpose of floor panel distribution and sound insulation, an asphalt sheet made of an asphalt composition is adhered to the floor panel. This asphalt sheet is heated on a vehicle painting line, etc., and adhered to the floor panel along the shape of the uneven parts.

[Problem that the invention seeks to solve]

However, as shown in FIG. 5, when the conventional floor carpet 1 is used, the asphalt sheet 4 is formed in a separate process from the process of forming the carpet layer 2 and the buffer layer 3. It is necessary to join the floor carpet 1 consisting of
In some cases, relatively flat uneven portions 7 are formed on the surface of the floor carpet 1, and in such cases, although the asphalt sheet 4 is adhered along the uneven portions 7, the floor carpet 1 is not shaped to follow the uneven portions 7. Since it is difficult to press-form, a gap 8 is likely to occur between the floor carpet 1 and the asphalt sheet 4, and the floor carpet 1 is attached to the floor panel 6.
It was not possible to bring the product into close contact with the skin, and there was a risk of worsening the feel.

An object of the present invention is to form an asphalt layer having a shape corresponding to the uneven parts of the floor panel at the same time as the process of forming a floor carpet comprising a carpet layer and a buffer layer, when uneven parts are formed on the floor panel. The present invention provides an economical method for manufacturing a vehicle floor carpet, which has excellent adhesion between the floor carpet and the asphalt layer, has excellent vibration damping effect, sound insulation effect and feel, and is highly economical.

[Means for solving problems]

The present invention has been made in view of the above-mentioned problems, and includes a floor panel for a vehicle, etc., which includes an uneven portion and a carpet layer and a buffer layer that are press-molded along the shape of the floor panel. A method for manufacturing a carpet, comprising: a lower mold formed with uneven portions corresponding to the uneven portions of the floor panel; and an upper mold molded to the lower mold;
A heated and molten asphalt composition containing asphalt as a main component is poured into the lower mold to form an asphalt layer having convex portions corresponding to the concave portions of the concave and convex portions of the lower mold, and then a buffer is applied to the top of the asphalt layer. A heated carpet material is placed on top of the cushioning material, an upper mold is molded to the lower mold, and a buffer layer made of a cushioning material and a carpet material are placed on top of the asphalt layer. The carpet layer is press-molded in a laminated state.

[Effect]

According to the present invention, an asphalt layer made of an asphalt composition, a buffer layer made of a buffer material, and a carpet layer made of a carpet material are press-molded in a laminated state,
There is no risk of gaps occurring between the asphalt layer and the buffer layer, and the adhesion is excellent, and when press-forming the carpet layer and buffer layer, there is no need to press-form to accommodate uneven parts of the floor panel, making work easier. This can improve efficiency.

〔Example〕

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the method for manufacturing a vehicle floor carpet according to the present invention will be outlined in detail below with reference to the drawings.

1 to 4 each schematically show an embodiment of the method for manufacturing a vehicle floor carpet according to the present invention, and a mold 11 used for carrying out the method of the present invention is a lower mold. 1
2, and an upper mold 13 that is mold-matched to the lower mold 12,
A floor panel (not shown) is provided approximately at the center of the lower mold 12.
A protrusion 14 corresponding to the protrusion extending in the front-rear direction is formed in the center of the floor panel (corresponding to the reference numeral 6 in FIG. 7) are respectively formed.

First, as shown in Figure 1, asphalt is the main component,
The asphalt composition 18 formed by suitably blending an oil agent and a filler is heated and melted, and this asphalt composition 18
is poured into the lower mold 12 at room temperature. This asphalt composition 18 flows into the concave portions of the concavo-convex portions 15 of the lower mold 12 and is molded into an asphalt layer 20 in which convex portions 19 corresponding to the concave portions are formed. When this asphalt layer 20 is cooled to, for example, about 50 to 80°C, this asphalt layer 2
As shown in FIG. 2, a cushioning material 22 such as felt material is provided on the top of the 0. The cushioning material 22 can be made of felt mixed with a thermoplastic resin, a foamed synthetic resin material, or the like.

Next, as shown in FIG. 3, a carpet material 24 is placed above the cushioning material 22. This carpet material 24 is formed from fibers 25 on the front side and a backing layer 26 on the back side, and the backing layer 26 of the carpet material 24 is placed in a heated state.

Next, as shown in FIG. 4, the lower mold 12 and the upper mold 13 are matched, and the heated carpet material 24 is laminated on the cushioning material 22 and press-molded, thereby forming the banking layer 26 of the carpet material 24 and the cushioning material. 22, a floor carpet 27 consisting of a carpet N28 of a desired shape and a buffer layer 29 is formed.

By disposing the buffer material 22 on the asphalt layer 20, then disposing the carpet material 24, and matching the lower mold 12 and the upper mold 13, the buffer layer 29 and the carpet J are formed.
While m2B is formed, the asphalt N20 and the buffer layer 29 are joined, and the asphalt J'1120 and the floor carpet 27 are press-molded into an integrated state.

When the floor carpet 27 and the asphalt layer 20 integrated with the floor carpet 27 are taken out from the mold 11,
It is possible to obtain a floor carpet that is attached to a floor panel.

〔Effect of the invention〕

The above is an embodiment of the method for manufacturing a vehicle floor carpet according to the present invention. According to this method, when uneven portions are formed on the floor panel, the carpet layer and the buffer layer can be separated. An asphalt layer having convex portions corresponding to the concave and convex portions of the floor panel can be integrally molded into the buffer layer of the provided floor carpet, and the adhesion between the asphalt layer and the buffer layer is excellent, and the distribution effect and sound insulation effect are achieved. It is possible to obtain a floor carpet with excellent texture and texture, and in particular, it is possible to press-form the uneven shape of the floor carpet to correspond to the uneven parts of the floor panel (it is not necessary to assemble the asphalt layer and the floor carpet separately). It is possible to significantly improve efficiency and obtain an economical method for manufacturing a vehicle floor carpet.

[Brief explanation of the drawing]

FIGS. 1 to 4 each schematically show an embodiment of the method for manufacturing a vehicle floor carpet according to the present invention.
The figure is a cross-sectional view of the asphalt composition poured into the mold, Figure 2 is a cross-sectional view of the same cushioning material installed, and Figure 3 is a cross-sectional view of the asphalt composition poured into the mold.
FIG. 4 is a sectional view of the same car vent material in a molded state, and FIG. 5 is a partial sectional view of a conventional vehicle floor carpet. In the figure, 11... Molding mold, 12... Lower mold, 13...
Upper mold, 15... Uneven part, 18... Asphalt composition, 19... Convex part, 20... Asphalt layer, 2
2... Cushioning material, 24... Carpet material, 27...
Floor carpet, 28...Carpet layer, 29...
・Buffer layer. Figure 1 Figure 1 Figure 2

Claims (1)

[Claims] In a method for producing a vehicle floor carpet, the method includes a carpet layer and a buffer layer that are press-molded according to the shape of the floor panel, the uneven portion being formed on a floor panel of a vehicle, etc., which corresponds to the uneven portion of the floor panel. It is equipped with a lower mold in which an uneven part is formed, and an upper mold to be molded to the lower mold, and a heated and melted asphalt composition containing asphalt as a main component is poured into the lower mold, and the uneven part of the lower mold is poured into the lower mold. An asphalt layer is formed with convex portions corresponding to the concave portions, and then a cushioning material is placed on top of the asphalt layer, a heated carpet material is placed on top of the cushioning material, and a heated carpet material is placed on the bottom mold. A method for producing a floor carpet for a vehicle, characterized in that an upper mold is matched, and a buffer layer made of a buffer material and a carpet layer made of a carpet material are integrally laminated and press-molded on top of the asphalt layer.