JPH0443395Y2 - - Google Patents

Description

[Detailed description of the invention] Purpose of the invention (industrial application field) This invention relates to carpets and other rugs laid in automobiles.

(Prior Art) Generally, rugs such as carpets installed in automobiles are provided with unevenness corresponding to the floor surface of the automobile, so that the rug is formed to be aligned with the floor surface.

That is, after forming a gray fabric by planting piles on a base fabric, melted polyethylene obtained by melting pellets into the gray fabric is poured into a T-shaped material at the tip of an extruder.
A flat rug is formed by pouring it onto the back side of the gray fabric through a mold die, solidifying it, and bashing the backing material. The back of this rug is lined with a shape-retaining sheet made of polyester, and then cold-pressed to create a shape that corresponds to the floor and side surfaces of a car. It is held in place and is held in place when placed on the floor of a car.

(Problem to be solved by the invention) However, in the above-mentioned rug, backing material is moved by moving the greige with rollers and melted resin is poured out using an extruder, which requires a large-scale equipment. The equipment is expensive and the manufacturing process is complicated.

Furthermore, since the shape retention of a deformed rug depends solely on the backing material, there is a need for a carpet with better shape retention capabilities.

This idea was made to solve the above problems, and the purpose was to create an automobile that could be manufactured easily, kept equipment costs low, and had an excellent shape retention function. The purpose is to provide rugs.

Structure of the invention (means for solving problems) Therefore, in this invention, the core material is covered with a shape-retaining material made of thermoplastic resin to form a nonwoven fabric, and a base material using this nonwoven fabric is constructed. A gray fabric is formed by planting piles on cloth, and a sheet-like backing material made of a synthetic resin material with shape retention properties is adhered to the back side of the gray fabric. The gist is that the mounting part is press-molded to have an uneven shape that corresponds to the shape of the installation surface.

(Function) That is, when the gray fabric is plastically deformed by press molding, an uneven mounting portion corresponding to the laying surface inside the vehicle is formed. The strength of the base fabric during press molding is ensured by the core material of the base fabric fibers constituting the gray fabric. In addition, since the shape-retaining material coated on the core material exhibits a plastic deformation effect, the shape-retaining function of the mounting portion corresponding to the laying surface is further strengthened by cooperation with the backing material, and the press forming The shape-retaining material, which is sometimes compressed, prevents the pile from coming off the base fabric.

(Example) Hereinafter, an example in which this invention is applied to a carpet for an automobile will be described in detail with reference to FIGS. 1 and 2.

As shown in Fig. 1, a pair of upper and lower rollers 1, 2
At the front (right side) of the crimping device 3, a pile 5 is planted on the base fabric 4 to form a gray cloth 14, and a backing material 6 made of sheet-like polyethylene is arranged below the gray cloth 14. A shape-retaining layer S (see FIG. 3) made of a synthetic resin material is pasted on. Then, the shape-retaining layer S is heated in advance, and the gray fabric 1
4 and backing material 6 are fed between both rollers 1 and 2 in a superposed state. Both rollers 1 of the crimping device 3,
2 is rotated in the direction of the arrow, grips the gray fabric 14 and backing material 6 supplied from the front, and sends them to the rear, and at this time, the pre-cooled lower roller 2 transfers the backing material 6 to the gray fabric 1.
4 to form a processed body 7.

As shown in FIG. 2, the base fabric 4 is formed of a nonwoven fabric using fibers 10 in which a core material 8 made of an ester-based resin material is covered with a shape-retaining material 9 made of a thermoplastic resin material such as polyethylene. ing.

After the workpiece 7 is taken out from the crimping device 3, it is placed between an upper mold 11 and a lower mold 12 shown in FIG. The upper mold 11 is installed to be movable in the vertical direction, and the lower mold 12 is fixed.
The mutually opposing surfaces 1 and 12 are formed in an uneven shape corresponding to the floor surface of a specific automobile. and,
After the upper mold 11 and the lower mold 12 are heated, when the upper mold 11 is lowered in the state shown by the solid line in FIG. The backing material 6 is transformed into the state shown by the two-dot chain line, and press molding is performed on the backing material 6 to form a carpet having an uneven mounting portion 13 that matches the installation surface inside the automobile, that is, the floor surface and the inner surface. Ru.

After that, when the upper mold 11 is raised and the carpet is taken out from the lower mold 12, the shape of the mounting part 13 is maintained by the action of the shape-retaining part 9 of the fibers 10 and the backing material 6, and the carpet is placed on the floor of the car. It is held in a predetermined shape corresponding to the surface.

In the above-mentioned carpet, the fibers 10 of the nonwoven fabric forming the base fabric 4 are covered with the shape-retaining material 9 made of a thermoplastic resin material on the core material 8 made of ester resin. 4
In addition to ensuring strength, the shape retaining material 9 exhibits a shape retaining effect. In addition, since the original shape-retaining effect of the backing material 6 is exhibited, the shape-retaining function is extremely high compared to conventional automobile carpets that rely only on the shape-retaining effect of the backing material 6.

Furthermore, since the crimping device 3 for crimping the sheet-like backing material 6 to the base fabric 4 is composed of two rollers 1 and 2, the configuration is extremely simple compared to the conventional bucking extruder.
The cost required for equipment is reduced.

In addition, during the press molding process, the fiber 1
The shape retaining material 9 of 0 is compressed, and the area around the part of the base fabric 4 where the pile 5 is planted is strengthened. Therefore, the pile 5 is prevented from coming off from the base fabric 4.

Note that this invention is not limited to the above-mentioned embodiments, and may be applied to other rugs such as carpets instead of carpets, or may be adapted to allow both the upper and lower molds 11 and 12 to be moved in the direction toward each other. It goes without saying that arbitrary changes can be made as long as they do not depart from the spirit of this invention.

Effects of the invention As detailed above, according to this invention, the core material constituting the base fabric fibers can ensure the strength of the base fabric during press molding, and the core material that constitutes the base fabric fibers can be used to ensure the strength of the base fabric during press molding. Since the shape-retaining material exhibits a plastic deformation effect, it is possible to easily form a mounting part with a shape that corresponds to the installation surface inside a car by press molding, and also to form a mounting part that corresponds to the installation surface in cooperation with the backing material. It is possible to further strengthen the shape retention function of the section, and furthermore, the shape retention material compressed during the press molding can prevent the pile from coming off from the base fabric, which is an excellent effect.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing the method of manufacturing a carpet for an automobile according to the invention, FIG. 2 is a cross-sectional view showing the press molding method, and FIG. 3 is a cross-sectional view showing the fibers of the nonwoven fabric constituting the base fabric. In the figure, 4 is a base fabric, 5 is a pile, 6 is a backing material, 8 is a core material, 9 is a shape-retaining material, 10 is a fiber, 1
3 is a mounting part, and 14 is a gray fabric.

Claims (1)

[Claims for Utility Model Registration] 1. A core material 8 is covered with a shape-retaining material 9 made of a thermoplastic resin material to constitute a fiber 10 forming a nonwoven fabric, and a pile 5 is formed on a base fabric 4 using this nonwoven fabric. The green fabric 14 is formed by planting, and the gray fabric 1 is further planted.
A sheet-like backing material 6 made of a synthetic resin material with shape retention properties is adhered to the back surface of the material 4, and an uneven mounting portion corresponding to the shape of the laying surface inside the vehicle is attached to the gray material 14 and the backing material 6. A rug for an automobile characterized by press-molding No. 13. 2. The core material 8 is made of an ester resin material,
The automobile rug according to claim 1, wherein the shape-retaining material 9 is made of polyethylene.