KR101805809B1 - Backing material and method to manufacture same, auxiliary mat for automobile - Google Patents

Abstract

A backing fabric of the present invention comprises: a bubble sheet; a pile yarn tufted on the bubble sheet after applying a crimp; and a fixing layer formed on the bubble sheet, and preventing the pile yarn from separating, wherein the pile yarn is composed of a plurality of filaments. Both ends of the pile yarn pass from one surface to the other surface of the pile yarn, and protrude from the other surface. A central part of the pile yarn in a lengthwise direction is latched by the one surface. End units of the filaments of the pile yarn passing through the other surface are scattered in different directions when the pile yarn is tufted on the bubble sheet.

Description

BACKING MATERIAL AND METHOD FOR MANUFACTURING THE SAME,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a backing fabric, a manufacturing method thereof, and an automotive auxiliary mat.

An automotive auxiliary mat is installed on the floor of the room to prevent the floor of the car from being contaminated by dirt and dust.

Backing materials for automotive auxiliary mats include thermoplastic resins such as polyvinyl chloride (PVC), styrene-butadiene-styrene (SBS), polyethylene terephthalate woven with needle punching and a nonwoven fabric made of polyethylene terephthalate (PET). Among them, the nonwoven fabric can be divided into the flame treatment type and the silicon (silicon) coating treatment product depending on the surface treatment method.

In the case of PVC and SBS used as the bottom material of automotive auxiliary mats, it contains volatile organic compounds (VOCs), which causes new car syndrome and it is very heavy as 1.5 ~ 2.5kg per 1 SQM. And it increases the weight of the vehicle, which is also the cause of the fuel economy increase.

In addition, since there is a lack of frictional property with the fibers of the floor of the automobile interior, a separate hook-shaped fixing means is required. Long-term use of auxiliary mats for automobiles may result in loosening of hooks and deterioration of fixing force, which may lead to slippage of vehicle auxiliary mats from the floor of the vehicle, which may be dangerous to the driver.

The lower surface of automotive auxiliary mats in the form of PET nonwoven fabric woven with a needle punching machine has a slight improvement in the unreasonability and the VOCs content is low and the weight of the auxiliary mats for automobiles is relatively light at 0.5-1 kg per 1 SQM level, Flame treatment and silicone treatment have also improved some of the fiber and surface friction of the floor of the room. However, when the flame treatment is performed, a small amount of odor and harmful substances remain, and there is a problem that the frictional property of Bulk Continuous Filament (BCF) is significantly lowered in the indoor flooring fibers of an automobile.

In addition, when the lower surface of the automotive auxiliary mat is subjected to the silicon treatment, a silicon coating process is separately required, which is expensive and is hardly universally used. There is a problem that the frictional property is slightly improved for BCF material among the floor fibers of automobile interior, but the frictional property for PET fiber is lowered.

In addition, there is a limit in improvement of the friction of the bottom surface of automotive auxiliary mat and surface of automobile under floor which is surface-treated to the nonwoven fabric material, so that a hook-shaped fixing means is still necessary.

In addition to the fixing means, a plurality of protrusions (SPIKE) which can be embedded in the fibers of the floor of the automobile are formed on the lower surface of the automotive auxiliary mat to prevent slippage. However, due to the formation of the projections, the weight of the mat was increased and the carrying performance of the automotive auxiliary mat was deteriorated. In addition, protrusions were formed on the indoor flooring fibers of automobiles.

Utility model registration No. 20-434416 (December 14, 2006) Utility Model Registration No. 20-407616 (2006.01.25.)

The present invention provides a technique for fixing an automotive auxiliary mat to the floor of an automobile without using a fixing means such as a hook or a ring.

A backing fabric according to an embodiment of the present invention includes a pile yarn tufted on a bubble paper after imparting a bubble paper or a crimp to the bubble paper and a fixing layer formed on the bubble paper to prevent separation of the pile yarn, Wherein the filament yarns are made of a plurality of filaments, both ends of the filament yarns passing through the other surface of the filament, the longitudinal center portion of the filament yarns hanging from the one surface, both ends of the filament yarns protruding from the other surface, When the filament yarn is tufted into the bubble paper, the ends of the filaments of the filament yarn passing through the other face are scattered and directed in different directions.

The pile maker can tune 40,000 to 12,000 sweat to 1 m ² of the paper.

The denier of the filament may be 150 to 500 d.

The length of both ends of the filament protruding from the bulge may be 5 to 10 mm.

The filament may have a virtual vertical axis and a horizontal axis, and the vertical axis and the horizontal axis cross each other at right angles to cross the imaginary center of the filament, and the length ratio between the vertical axis and the horizontal axis is 1 : 1 to 1: 5.

Sectional area of the filament increases from both ends of the horizontal axis toward the vertical axis direction.

An automotive auxiliary mat according to an embodiment of the present invention includes a backing fabric configured as described above, a surface layer positioned on the backing fabric and having surface pile yarn tufted on the surface pile fabric, and an adhesive layer joining the surface layer and the backing fabric .

And a surface fixing layer formed on the surface bubble to fix the surface pile so that the surface pile does not separate from the surface protection film.

A method for fabricating a backing fabric according to an exemplary embodiment of the present invention includes the steps of fabricating a filament yarn composed of a plurality of filaments through a process of mixing, cooling, and drawing a raw material, tufting the filament yarn at predetermined intervals in a bubble paper, Applying a ethylene-vinyl acetate copolymer (EVA) or styrene butadiene latex (SBR latex) to the base paper to form a fixing layer, and drying the fixing layer, The filament is thermally treated at 150 to 200 ° C to crimp the pile yarn in a yarn manufacturing step. In the tufting step, when the pile yarn is tufted to the bubble yarn, You can head.

According to the embodiment of the present invention, the filament yarn is tucked on the lower surface of the automotive auxiliary mat, and the ends of filaments of filament yarns are scattered and bent in different directions, The auxiliary mats for an automobile can be fixed to the floor fibers of an automobile without an additional fixing device since the auxiliary mats for an automobile are fixed while being pressed by the driver's load.

According to the embodiment of the present invention, since the filaments of the filament yarns are scattered and directed in different directions, and the end portions of the filaments are fixed to the underfloor fibers of the automobile, they do not have a ring like a general Velcro, The occurrence of damage is minimized.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded cross-sectional view of an automotive auxiliary mat according to an embodiment of the present invention; FIG.
Fig. 2 is an enlarged view of a portion A in Fig. 1; Fig.
3 is an enlarged photograph showing a section of the filament of FIG.
Fig. 4 is an assembled state diagram of Fig. 1; Fig.
Fig. 5 is a photograph showing the bottom surface of the automotive auxiliary mat of Fig. 2; Fig.
6 is a block diagram illustrating a method of fabricating a backing fabric in accordance with an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily carry out the present invention. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like parts are designated with like reference numerals throughout the specification.

The backing fabric according to the embodiment of the present invention can be applied to an auxiliary mat for an automobile which is an embodiment of the present invention. Hereinafter, an auxiliary mat for an automobile to which a backing fabric is applied will be described.

An automotive auxiliary mat according to an embodiment of the present invention will now be described with reference to FIGS. 1 to 5. FIG.

FIG. 1 is an exploded sectional view showing an automotive auxiliary mat according to an embodiment of the present invention, FIG. 2 is an enlarged view of a portion A of FIG. 1, FIG. 3 is an enlarged photograph showing a cut- Fig. 4 is a combined state view of Fig. 1, and Fig. 5 is a photograph showing the bottom surface of the automotive auxiliary mat of Fig.

1 to 5, an automotive auxiliary mat 1 according to the present embodiment includes a surface layer 10, a surface fixing layer 20, an adhesive layer 30, a backing fabric 40, and a backing fixing layer 50 So that the backing fabric 40 is not caught by the fibers 101 of the indoor floor 100 of the vehicle when installed on the indoor floor 100 of the vehicle.

The surface layer 10 includes a surface base paper 11 having a predetermined width and a surface pile yarn 11 punched in a turntable manner on the surface base paper 11, (1).

The surface protective paper 11 may be formed of a non-woven fabric made of polyethylene terephthalate (PET) or a polypropylene (PP) fabric.

The surface pile yarn 12 may be made of nylon, polypropylene (PP), polyethylene terephthalate (PET), or polyethylene (PE). The surface pile yarn 12 is densely buried in the surface protective paper 11 through the tufting device.

A part of the surface filament yarn 12 is located on the lower surface of the surface protection film 11 and an end of the surface filament yarn 12 protrudes from the upper surface of the surface protection film 11 through the surface protection film 11 by a predetermined length . The surface pile yarn 12 has a predetermined buffering force by the protruded length and can provide comfort to the user.

The detailed structure of the surface layer 10 can be applied to a known automotive auxiliary mat configuration, and a detailed description of the structure will be omitted.

The surface fixing layer 20 is formed on the lower surface of the surface protective paper 11 and fixed so that the surface pile yarn 12 does not separate from the surface protective paper 11. [ The surface fixing layer 20 may be formed of an ethylene-vinyl acetate copolymer (EVA) or a styrene butadiene latex (SBR latex).

However, the surface fixing layer 20 may be omitted when the surface pile yarn 12 is not formed on the surface layer support 11.

The backing fabric 40 includes a foil paper 41 and a pile yarn 41 and is bonded to the surface layer 10 via an adhesive layer 30. The backing fabric 40 supports the surface layer 10 so that it does not slip when the automotive auxiliary mat 1 is installed on the floor 100 of the automobile.

The adhesive layer 30 may be formed of low density polyethylene (LDPE), ethylene-vinyl acetate copolymer (EVA), or the like. The adhesive layer 30 can be variously applied as long as it can bond the backing fabric 40 and the surface layer 10 together.

The base paper 41 has a predetermined width. The upper surface of the base paper (41) is connected to the lower surface of the surface base paper (11) through the adhesive layer (30). Since the detailed structure of the base paper 41 is the same as that of the surface base paper 11 described above, a duplicated description will be omitted.

The filament yarns 42 are formed by twisting a plurality of filaments 42a, 42b, ... 42n and crimping the filaments 42 into a bulge 41 with a tufting device in a curled form.

At this time, the pile yarn 42 may be stuck with 40000 perspiration to 120000 perspiration in 1 m ² of the paper 41. At this time, 200 to 400 sweat can be stuck in 1 m in the horizontal direction and 200 to 400 sweat in 1 m in the vertical direction. In the case where the filament yarn of the filament yarn 42 is less than 40,000 stitches, the binding ratio between the filament yarn 42 and the underfloor fiber of the automobile is lowered. When the filament yarn diameter exceeds 12,000, the filament yarn becomes dense, .

The end portions of the filaments 42a, 42b ... 42n of the filament yarns 42 face the opposite direction to the end portions of the surface filament yarns 12. The ends of the filament yarns (42) protrude from the lower surface of the base paper (41). The filaments 42a, 42b, ..., 42n of the protruding portion of the filament yarn 42 are tufted on the bulge 41 and scattered and remain bent in different directions. The filaments 42a, 42b ... 42n may become entangled with the indoor floor 100 fabric (nonwoven fabric) 101 of the vehicle when the automotive auxiliary mat 1 is installed on the floor of an automobile.

The deniers of the filaments 42a, 42b ... 42n may be between 150 and 500d. The number of the filaments 42a, 42b ... 42n may be 4 to 30. The denier of the filer 42 may be 600 to 15,000.

If the filament yarn 42 is less than 600 d, the bonding force may be lowered due to the decrease in the number of the filaments 42 a, 42 b,... 42 n, and if it exceeds 15,000 d, the manufacturing cost may increase.

On the other hand, the filaments 42a, 42b ... 42n may have a vertical axis V and a horizontal axis H, as shown in Figs. 3A and 3B. Here, the vertical axis (V) is the longest portion in the forward and backward directions when the filament is sectioned along the width direction, and the horizontal axis (H) is the longest portion in the left and right directions. The vertical axis (V) and the horizontal axis (H) intersect perpendicularly at the virtual center of the filament. The length ratio of the vertical axis (V) to the horizontal axis (H) may be 1: 1 to 1: 5. The filaments are elongated in a circular or one direction as shown in Figs. 3 (a) and 3 (b).

Sectional area of the filaments 42a, 42b ... 42n increases from both ends of the horizontal axis H toward the vertical axis V, The outer circumference of the filament may be formed in various shapes such as a curved surface, a multi-tier, and a wave. On the other hand, if the ratio of the vertical axis to the horizontal axis is close to 1: 1, the cross-sectional shape may be formed of triangular, square, or the like.

As the vertical axis and the horizontal axis are formed closer to 1: 1, the uprightness of the filaments is increased, and the filament yarn penetrates into the bottom surface fiber of the automobile and can be entangled.

The central portion of the tufted pile yarn 42 is positioned between the adhesive layer 30 and the upper surface of the base paper 41 and both ends protrude from the lower surface of the base paper 41. The filaments 42a, 42b ... 42n of the pile yarn 42 located between the adhesive layer 30 and the upper surface are connected to each other and the filaments 42a, 42b ... 42n ) Are scattered and bent in different directions.

The projecting length of the pile yarn 42 from the lower surface of the base paper 41 may be 5 to 10 mm. If the protruding length of the pile yarn 42 is less than 5 mm, the entanglement and buffering force of the automobile with the bottom floor fiber of the automobile is lowered. When the protruding length of the filament yarn 42 exceeds 10 mm, the filaments 42a, 42b ... 42n are easily collapsed, and the entanglement of the filaments 42a, 42b, ... 42n with the floor fibers of the automobile is not smooth.

The pile yarn 42 may be made of nylon, polypropylene (PP), or polyethylene terephthalate (PET). The pile yarn 42 has a weight of 200 to 600 g / m ² .

The backing fixing layer 50 is formed between the adhesive layer 30 and the upper surface of the base paper 41 and is fixed so that the pile yarn 42 does not come off from the base paper 41. Since the detailed structure of the backing fixing layer 50 is the same as that of the surface fixing layer 20 described above, a duplicated description will be omitted.

Next, the backing fabric manufacturing method will be described.

Referring to FIG. 6, a method for fabricating a backing fabric according to an embodiment of the present invention includes a pile yarn manufacturing step S10, a filing step S20, a fixed layer forming step S30, and a fixed bed drying step S40 .

Pile yarn 42 made of filaments 42a, 42b ... 42n is manufactured through raw material mixing, extrusion, cooling, drawing, and crimping in a filament production step S10. A crimp is given to the filament yarn 42 so that the filament yarn 42 is curled. When forming the filament yarn 42, the filament yarn 42 is passed through a narrow and long pipe after completion of the drawing operation, and a filament yarn is applied to the filament yarn 42 at a temperature of 150 to 200 ° C.

In the file typing step S20, the crimped filament yarn 42 is tufted to the foil paper 41 by using the tufting device. The end portions of the filaments 42a, 42b ... 42n of the filament yarns 42 are scattered and directed in different directions during the process of tufting the filament yarn 42 to the bulge 41.

An ethylene-vinyl acetate copolymer (EVA) or a styrene butadiene latex (STA) is applied to the base paper 41 so that the pile yarn 42 does not separate from the base paper 41 in the fixed layer forming step S30 (SBR latex)) is applied to form the fixed layer 50.

In the fixed layer drying step (S40), the fixed layer (50) is dried by applying heat having a predetermined temperature to the fixed layer (50) to complete the production of the backing fabric (40).

The backing fabric 40 and the surface protection paper 11 with the surface pile yarn 12 thus manufactured are combined with the backing fabric 40 by using the adhesive layer 30 to form the automotive auxiliary mat 1, (2).

Table 1 below shows an evaluation table for slippage of the automotive auxiliary mats.

In the evaluation of non slip performance of auxiliary mats for automobiles, since there are no test items or specifications related to automobile companies, self test standards were set and evaluated.

There are two types of N / P (Needle Punching) material and T / F Tufting material on the floor of automobile interior.

The slipperiness evaluation method is as follows.

1) Prepare the fibers that make up the floor of the car.

2) An eyelet mounting hole is formed on an automotive auxiliary mat cut to 25 cm X 25 cm and placed on the fabric that forms the floor of the car.

3) Pull the push-pull gauge to the eyelet mounting hole, check the instrument panel, and check the value of the highest recorded force.

4) Repeat the same test by putting 1kg and 3kg weight on the automobile auxiliary fabric mat and check the result.

As a result of slip evaluation of automotive auxiliary mats, it can be seen that slip does not occur remarkably even in comparison with plastic materials such as PVC and SBS which are conventional non-slip prevention techniques, and nonwoven materials in which the sliding is partially improved. It can be seen that the auxiliary mats for automobiles are fixed on the floor of the vehicle without a separate fixing device.

As can be seen from the comparison table shown in the following Table 2, the automotive auxiliary mat to which the pile according to the present embodiment is applied is made lighter than conventional regenerated PVC, SBS, PET nonwoven fabric + S / Dot, VOCs, Is superior.

The auxiliary mats according to the present embodiment are formed by piling filaments in a tufting manner on the bottom surface of the automotive auxiliary mat. The ends of the filaments of filaments are scattered and bent in different directions, do. And is pressed and fixed by the driver's load, it is possible to fix the automotive auxiliary mat with the flooring fiber of the vehicle without the fixing device.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, Of the right.

1: Automotive auxiliary mat 10: Surface layer
11: surface protection paper 12: surface pile paper
20: surface fixing layer 30: adhesive layer
40: backing fabric 41:
42: file company 42a, 42b ... 42n: filament
421: open-loop files 422: closed-loop files
50: fixed layer

Claims (9)

However,
A method for producing a foamed yarn comprising the steps of applying a crimp,
A fixing layer formed on the base paper and preventing the pile yarn from separating from the fixing paper
/ RTI >
Wherein the filament yarns are made of a plurality of filaments and have a vertical axis and a horizontal axis in a cross-sectional state where the filament is cut along the width direction, wherein the vertical axis and the horizontal axis cross each other at a virtual center of the filament, And increases from both ends of the horizontal axis toward the vertical axis direction
Backing fabric. The method of claim 1,
Wherein the pile fabric has a backing fabric in which 40,000 sweat to 120000 sweat are tufted on 1 m ² of the paper. The method of claim 1,
Wherein the filament has a denier of 150 to 500 d. The method of claim 1,
Wherein a length of the protruding end of the pile yarn from the bulge is 5 to 10 mm. The method of claim 1,
Wherein the length ratio of the vertical axis to the horizontal axis is 1: 1 to 1: 5. The method of claim 1,
Wherein the pile yarns are passed through opposite sides of one side of the base paper, and a longitudinal center portion of the pile yarns is hooked on the one side, both ends of the pile yarns protrude from the other side, and the pile yarns are tufted The end portions of the filaments of the pile yarn passing through the other surface are scattered and are directed in different directions
Backing fabric. A backing fabric as defined in any one of claims 1 to 6,
A surface layer positioned on the backing fabric and having a surface pile yarn tufted on the surface pile fabric,
An adhesive layer for bonding the surface layer and the backing fabric,
Containing
Automotive auxiliary mats. 8. The method of claim 7,
Further comprising a surface fixing layer formed on the surface bubble and fixing the surface pile so that the surface pile does not separate from the surface bubble. Preparing a filament yarn composed of a plurality of filaments through raw material mixing, cooling, and stretching;
Tufting the pile yarn at predetermined intervals in the bubble;
Forming a fixing layer by applying an ethylene-vinyl acetate copolymer (EVA) or styrene butadiene latex (SBR latex) to the base paper; and
Drying the fixed bed
/ RTI >
In the filament manufacturing step, a filament is heated to 150 to 200 ° C to crimp the filament yarn. In the tufting step, when the filament yarn is tufted onto the bubble filament, the ends of the filament are scattered Direction,
Wherein the filament yarns are made of a plurality of filaments and have a vertical axis and a horizontal axis in a cross-sectional state where the filament is cut along the width direction, wherein the vertical axis and the horizontal axis cross each other at a virtual center of the filament, And increases from both ends of the horizontal axis toward the vertical axis direction
Backing fabric manufacturing method.

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