JPH0369704B2 - - Google Patents

Description

[Detailed description of the invention] The present invention relates to an automobile floor structure.

Conventionally, the floor structure of an automobile is constructed by placing a carpet formed in a shape that follows the shape of the automobile floor substrate on the floor substrate. To impart moldability to the carpet, the carpet is lined with a plastic film such as polyethylene film or ethylene-vinyl acetate copolymer film as an underlay. Furthermore, in order to provide sound insulation, felt is pasted on the back side of the carpet through the plastic film, or a so-called mask mask made by mixing a large amount of filler with the plastic film to make it thicker is pasted on the back side of the carpet. or However, the above-mentioned polyethylene film and ethylene-vinyl acetate copolymer film have poor shape retention, and the above-mentioned sound insulation means require the troublesome process of pasting a plastic film on the carpet and then pasting felt on top. Otherwise, a large amount of expensive plastic material must be used. Furthermore, if beads for reinforcement are formed on the floor substrate, or if harnesses or ducts are installed on the floor substrate, unevenness due to these may be detected from the carpet surface, making it difficult to walk on, and The drawback was that there was a risk of tripping and falling.

The present invention aims to improve the above-mentioned conventional drawbacks and is based on the use of a broken material molded product using a urethane prepolymer as a carpet underlay.

The present invention will be explained in detail below.

The most desirable material used in the present invention is short fibers separated by pulverization from the waste materials of textile products such as carpets and felts, but other pulverized materials such as plastics and asphalt sheets separated from the above-mentioned waste materials can also be used.

The urethane prepolymer used in the present invention is a polyvalent isocyanate such as tolylene diisocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, hydroxy polyester, polyoxypropylene glycol, poly(oxypropylene), poly(oxyethylene), etc. )
glycol, polyoxypropylene triol,
It is a prepolymer of terminal isocyanate obtained by reacting with a polyhydroxy compound such as poly(oxypropylene) or poly(oxyethylene) triol, and is usually treated with an organic solvent such as methylene chloride, methyl ethyl ketone, toluol, or ethyl acetate. It is said to be a solution of about 50% by weight. The prepolymer is polymerized into polyurethane by contacting with a compound having active hydrogen such as water, alcohol, or amine.

The above-mentioned scrap material is mixed, for example, in a mixer, and the prepolymer is sprayed onto the mixture by a sprayer or the like to mix thoroughly. The mixing ratio is from 50:50 to 90:10, preferably from 70:30 by weight of debris to prepolymer solution.
The ratio is about 80:20.

The above mixture is placed in the lower mold 1B of a mold 1 consisting of an upper mold 1A having a mold surface of a predetermined reinforcing bead as shown in FIG. 1, and a lower mold 1B having a mold surface of a predetermined floor board shape. The upper mold 1A is set with a thickness of
At this time, steam is introduced into the lower mold 1B from the steam pipe 2 to lower the lower mold 1B.
When steam is ejected from the steam holes 3 formed on the surface and comes into contact with the mixture, the prepolymer in the mixture polymerizes to form polyurethane and firmly adheres the broken materials. In this way, an underlay is obtained in which the lower surface is formed into a shape that matches the shape of the predetermined floor substrate and the upper surface is formed into the predetermined floor shape. Since the underlay has poor surface smoothness, in order to attach it to the carpet, a plastic sheet made of polyvinyl chloride, polyethylene, polypropylene, polyamide, etc. must be attached to the top surface of the molded product by gluing, fusing, or tacking. is desirable. The plastic sheet may be formed into a shape corresponding to the upper surface shape of the molded product by vacuum forming or the like before being bonded to the molded sheet. A carpet 5 is attached to the upper surface of the base laminate material 4 consisting of the underlay 4A and the plastic sheet 4B thus obtained by adhesion, fusion, etc. to obtain a floor covering as shown in FIG. 2. The floor covering has reinforcing beads 6 as shown in FIG.
It is fitted onto the floor substrate 6 having A.

In the case of this embodiment, the unevenness caused by the reinforcing bead 6A is not perceivable from the surface of the carpet 5.

The above-mentioned underlay is highly elastic and has good sound insulation properties, but as shown in FIG. 4, an asphalt sheet, It may have a three-layer structure in which viscoelastic sheets 14C such as unvulcanized rubber sheets and thermoplastic soft synthetic resin sheets are sandwiched. In the above configuration, the sound insulation properties are further improved due to the sound wave damping effect of the viscoelastic sheet.

In the case of the above structure, the broken material-prepolymer mixture is set on the surface of the lower mold 1B, an asphalt sheet is placed on top of it, and the mixture is further set on top of it and molded in the same manner. Furthermore, similar sound insulation properties can be obtained by attaching the viscoelastic sheet to one or both sides of the underlay instead of the sandwich structure.

Even if the plastic sheet 4B and the underlay 4A are laminated together at the same time by overlapping the plastic sheets 4B when the underlay 4A is molded, the plastic sheet 4B and the underlay 4A can be laminated together after the underlay 4A is molded.
Either can be pasted together. However, the plastic sheet 4B is not absolutely necessary.

FIG. 5 shows yet another embodiment. In the figure, a harness 7 through which an electric wire 8 is inserted is actually arranged at a predetermined location of the floor board 6, and the bottom surface of the underlay 24A is the floor board 6 including the harness 7.
The upper surface is molded into a predetermined floor shape, and the carpet 5 is adhered via the adhesive layer 24B. In the case of this embodiment, not only the unevenness due to the reinforcing bead 6A but also the convexity due to the harness 7 is not detected from the surface of the carpet 5.

As described above, the present invention uses a molded product of a mixture of scrap wood and urethane prepolymer as the underlay of the carpet, so crushed waste materials such as textile products and plastic products can be used as the scrap material, and unevenness on the floor substrate can be eliminated. It can be manufactured very cheaply even if it is thick enough to absorb it, and since urethane prepolymer is used as a binder for the broken material, high molding temperatures are not required, so thermal energy efficiency is good, and the bottom surface shape is good. Moreover, the upper surface shape can be easily molded and the shape retention property is extremely good. Therefore, unevenness caused by reinforcing beads formed on the floor substrate, harnesses, ducts, etc. arranged on the floor substrate are not detected at all from the carpet surface.
To provide a floor structure that is easy to walk on and has no risk of falling, and therefore has a good usability. Further, the molded sheet according to the present invention has excellent sound insulation properties, and the sound insulation properties are further improved by laminating viscoelastic sheets.

[Brief explanation of drawings]

Figures 1 to 3 relate to one embodiment of the present invention; Figure 1 is a perspective view of a mold used in this embodiment, Figure 2 is a side sectional view of a floor covering, and Figure 3 is a side sectional view of a floor covering. FIG. 4 is a side sectional view of the floor structure of another embodiment, and FIG. 5 is a side sectional view of the floor structure of still another embodiment. In the figure, 1...molding mold, 1A...upper mold, 1B...
Lower mold, 2...Steam pipe, 3...Steam hole, 4A,
14A, 24A...Underlay, 5...Carpet.

Claims (1)

[Scope of Claims] 1. An underlay whose lower surface has a shape that conforms to the shape of an uneven floor substrate of an automobile and whose upper surface has a predetermined floor shape is fitted onto the automobile floor substrate, and the underlay is placed on the underlay. In the floor structure of an automobile on which a carpet is mounted, the underlay is manufactured by filling a mold with a mixture of scrap wood and urethane prepolymer, and hardening the urethane prepolymer by contacting with moisture. An automobile floor structure characterized by: 2. An underlay whose lower surface has a shape that fits the uneven floor substrate of an automobile and whose upper surface has a predetermined floor shape is fitted onto the automobile floor substrate, and a viscoelastic sheet is placed on the underlay. In the floor structure of an automobile on which carpet is mounted, the underlay is manufactured by filling a mold with a mixture of scrap wood and urethane prepolymer, bringing it into contact with moisture, and curing the urethane prepolymer. An automobile floor structure characterized by: