JPH0747557A - Car floor carpet manufacturing method - Google Patents

Abstract

(57) [Abstract] [Purpose] The development of a construction method that does not require a composite film to prevent the exudation of urethane due to injection foaming when forming the cushion layer on the back surface of an automobile floor carpet, is lightweight, and improves sound insulation. [Structure] Applying resin to a urethane foam sheet and adjusting the density to create a high-density urethane layer and a low-density urethane layer,
These are heated as needed during the molding of the carpet, and the low-density urethane layer and the high-density urethane layer are laminated in this order on the mold, and the surface of the carpet on which the backside resin has been heated and melted is laminated thereon and immediately cold pressed.

Description

Detailed Description of the Invention

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile floor carpet, which is characterized by a back cushion layer.

2. Description of the Related Art Conventionally, an automobile in which a urethane foam stock solution is injected into a space after a molded carpet is set in an injection mold and a urethane layer having a density difference in a thickness direction and a horizontal direction is formed by setting temperature conditions for foaming. The floor carpet is described in Japanese Utility Model Publication No. 4-42111.

[0002]

[Problems to be Solved] However, the injection foaming method has a problem that the urethane easily exudes from a portion where the carpet is locally stretched at the time of molding by the foaming pressure. On the other hand, a composite film of polyamide and polyethylene is laminated with the polyethylene side facing the carpet resin surface to prevent pinholes that occur during molding,
It deals with the exudation of urethane during injection foaming. Therefore, there is a problem in that the composite films are stacked and the cost is increased in addition to being heavy. Therefore, the present invention has an object to solve such a problem, and another object thereof is to manufacture an automobile floor carpet which is lighter and has improved sound insulation.

[0003]

According to the present invention, "the density of resin attached to a urethane foam sheet is 0.07-0.12 g.
/ Cm ³ of urethane foam layer (A) and optionally urethane foam layer (B) having a density of 0.03-0.05, heated to heat the carpet surface of resin (A). The problem could be solved by laminating the layer (B) on a molding die and cold pressing. The urethane foam used here is obtained by cutting the urethane foam to a predetermined size, slicing it, and adjusting the density by coating and impregnating with a resin. Further, the resin functions as an adhesive and also exerts moldability during molding. As the resin, acrylic resin, vinyl acetate resin, olefin resin, vinyl chloride resin, thermoplastic resin such as petroleum resin, or two-pack type urethane can be used. The resin may be processed by a method such as melt coating of an emulsion or solution coating block.

A tufted carpet and a needle carpet are generally used for the surface fiber layer of the carpet, and a synthetic resin such as polyethylene, ethylene / vinyl acetate is used for the back surface of the tufted carpet, and a filler is included. It is melt coated. As the needle carpet, the one in which the resin layer is formed as in the tuft carpet, or the one in which the binder emulsion is not applied to the back surface of the carpet and dried is used.

Molding and unifying are carried out by heating a carpet and resin-adhered urethane to melt the resin, setting them on the surface of a molding die, and cold pressing between the dies to form the carpet and integrally integrate the urethane layer by welding. Can be done at the same time.
In the case of two-component type urethane impregnation, it is necessary to laminate in a non-solidified state, in which case heating is not necessary. The use of two urethane layers having different densities is for the purpose of weight reduction and improvement of sound insulation, which is another object of the present invention. The upper layer of the urethane foam layer has a density of 0.07-0.
The reason why it is set to 12 g / cm ³ is that if it exceeds 0.12 g / cm ³ , it may be hard due to clogging of urethane foaming holes, and it may be difficult to reduce the weight. If it is less than 0.07 g / cm ³ , the effect of sound insulation cannot be obtained. Layer thickness is 3-10mm
Is appropriate. Lower layer urethane foam has a density of 0.0
3-0.05 g / cm ³ is suitable range 0.03 g / c
If it is less than m ³ , the repulsive force will be insufficient and it will be difficult to manufacture it stably. If it exceeds 0.05 g / cm ³ , the effect of weight reduction is lost. Layer thickness is 5-50mm
Is a commonly used range. The layer thickness may be set within the above range so that the average urethane layer has a lighter weight than the average density of 0.06 g / cm ³ .

[0006]

[Example 1-2] 120 g / ^m backside ethylene-vinyl acetate nylon yarn polyester spunbonded fabric base was 520 g / ^{m 2} titanium Futingu of ² (vinyl acetate content: 2
2 kg / m consisting of 25% by weight of 8%) and 75% by weight of Calpet A (calcium carbonate masterbatch manufactured by Nitto Koka Kabushiki Kaisha)
² was melt-coated to produce a carpet. On the other hand, the two-component urethane foam undiluted solution is jetted from the mixing jet head onto the belt and passed through a heat furnace to produce a urethane block layer having a thickness of about 10 cm, which is then cut to a predetermined size to have thicknesses of 5 mm and 15 m.
sliced into m. The density was 0.03 g / cm ³ . Applying ethylene / vinyl acetate hot melt adhesive to 5 mm layer of urethane foam on both sides, the density is 0.07
g / cm ³ and 0.12 g / cm ³ were prepared.

The density of 0.03 g /
A 15 mm thick urethane foam layer with a cm ³ thickness is set, and a density of 0.12 g / cm ³ or 0.07 g is set on the urethane foam layer.
/ Cm ³ urethane foam layer with a thickness of 5 mm is laminated,
The back side of the carpet, which was heated in a heating furnace to melt the backside resin layer, is laminated with the urethane foam side facing the urethane foam side, and immediately cold pressing is performed between the upper and lower molds to obtain a shape that corresponds to the shape of the car floor surface. A urethane layer having different densities was formed while being molded. In this method, urethane does not exude on the surface of the carpet at all, and it becomes unnecessary to laminate the composite film to prevent pinholes. Place the flat part of the molded product on a 0.7 mm iron plate.
A test for sound wave transmission loss was conducted with the urethane foam side facing with a damping material of Kg / m ² attached. As a result, as shown in FIG. 2, the weight is lighter than the conventional product and the sound wave transmission loss is improved.

[0008]

[Comparative Example 1] Using the same carpet as in the example, the resin layer was heated in a heating furnace to melt and the resin layer was set in a mold, and the molded carpet cold pressed between the upper and lower molds was set in a urethane injection foam mold. The urethane foaming undiluted solution was injected into the void on the back side of the carpet for foaming. Urethane bleeds from some deep drawing points. The density of the foam layer was 0.06 g / cm ³ .

[0009]

Comparative Example 2 Using the same carpet as in the example, the same urethane foam was sliced into 20 mm, and the same hot melt adhesive as in the example was applied to this to obtain a density of 0.06 g /
A cm ³ urethane layer was formed. This was set in the lower mold as in the example, and thereafter the same processing as in the example was performed to measure the sound wave transmission loss. The results are shown in FIG. This product has a lower sound wave transmission loss though it is heavier than the example.

[0010]

[Comparative Example 3] The same carpet as in Example was used, and the same urethane foam was sliced into 5 mm and 15 mm to obtain 5 mm.
On the other hand, the same hot melt adhesive as in the example was applied to both sides to give a density of 0.07 g / cm ³ . First, set 15 mm urethane in a predetermined position of the lower die of the molding die, stack 5 mm urethane having a density adjusted thereon, and stack the resin surface on which the back surface resin of the carpet is heated and melted on the urethane side. Immediately thereafter, cold pressing was performed between the molds, and the urethane layer was bonded simultaneously with the molding. FIG. 2 shows the sound wave transmission loss of the sample cut from the same place as that of the example. As a result, there was almost no improvement in sound wave transmission loss.

[0011]

EFFECT OF THE INVENTION Since the present invention uses the method of forming the urethane foam layer on the back surface of the automobile floor carpet by welding the previously manufactured urethane layer at the time of molding, it is compared with the urethane layer formation which is carried out by the conventional injection foaming method. It was possible to completely eliminate the phenomenon of poor oozing of the urethane carpet surface. In addition, needle carpets that could not be used in the injection foaming method can now be applied to carpets with only emulsion coating on the back side. Furthermore, it does not require the lamination process of the composite film that has been conventionally adopted as a measure against pinholes, and it is lightweight and sound-insulating by the manufacturing method in which two layers with different densities are adjusted by using resin and bonded together. It was possible to obtain a composite urethane cushion layer having excellent cost-effectiveness.

[Brief description of drawings]

FIG. 1 is a sectional view of the floor carpet of the present invention. FIG. 2 is a diagram showing the sound wave transmission loss with respect to each frequency of the present invention and the comparative example.

[Explanation of symbols]

 1 Carpet Fiber Layer 2 Carpet Backside Resin Layer 3 Carpet Backside Cushion Layer 31 Cushion Layer High Density Layer 32 Cushion Layer Low Density Layer

Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI technical display location // B29C 65/02 7639-4F B29K 75:00 105: 04 105: 10 B29L 9:00 31:58

Claims (1)

[Claims] 1. A urethane foam layer (A) having a resin adhesion density of 0.07-0.12 g / cm ³ on a urethane foam sheet and a resin adhesion density of 0.03-if necessary.
Molding by heating a urethane foam layer (B) of 0.05 g / cm ^{3 if} necessary, laminating (A) layer and then (B) layer on a heated carpet resin surface in a molding die and cold pressing. Manufacturing method of integrated car floor carpet. [0001]