JPH079904A - Vehicle carpet and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] [Object] To provide a vehicle carpet having a structure in which chip waste does not adhere to the surface of a counterpart carpet even if the carpets are stacked, and a method for manufacturing the same. [Structure] In a vehicle carpet 1 in which an insulator 4 made of chip urethane is integrally laminated on the back surface of a car pad, a lining 5 attached to the back surface of the insulator 4 and relatively larger than the insulator 4 is used.
Are sandwiched between the lining 5 and the back surface of the backed car pedal. In addition, in the method of manufacturing a vehicle carpet to be compression-molded, after the relatively large lining 5 is integrated on the back surface of the insulator 4, the lining 5
Attach the insulator 4 with the lining 5 inside the mold.
Are arranged so that they are located below, and the carped raw fabric A after the backing process is stacked and integrated on the insulator 4 in a state where the peripheral portion of the lining 5 is locked to the positioning pins 13 provided on the molding die side. Compression molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle carpet laid on a passenger compartment floor and a method for manufacturing the same.

[0002]

2. Description of the Prior Art Carpets for vehicles are usually manufactured by the method shown in FIGS.
As illustrated in FIG. 1, the three-dimensional object is molded according to the floor shape. The carpet 52 shown in the figure is an example of a tufted carpet in which a cut or loop pile 53 is formed, and a backing treatment is performed by applying latex or synthetic resin emulsion to the back surface of the cut pile.
4 has an insulator 55 of a predetermined thickness provided on the back surface thereof.

The backing material 54 imparts pile retaining strength, shape retention and formability. The insulator 55 is made of chip urethane, and is shaped, for example, using a molding die under predetermined conditions, and then placed in a molding die that molds a backed carpet into a predetermined shape. The backing-treated carpet is overlaid on the carpet, and the carpet is integrated at the same time as compression molding.

Then, the carpet 52 after molding is taken out from the molding die, a predetermined number of the carpets 52 are stacked and conveyed to an assembly line of an automobile or the like, and incorporated in the floor of the passenger compartment, as shown in FIG.

[0005]

In the conventional carpet 52 described above, when a plurality of the carpets 52 are stacked, the chips of the chips forming the insulator 55 adhere to the loop pile 53 of the carpet 52 which is located below. Easy to get dirty,
This is a problem because it requires work such as removing dust before and after mounting on the vehicle body.

[0006] In order to solve such a problem, when the carpet 52 is piled up, a paper or the like is inserted between them and the insulator 5 is inserted.
It is also possible to prevent the scrap 5 from adhering to the carpet 52 of the other party by not directly contacting the carpet 5. However, in this method, in addition to the cost required for inclusions such as paper, since the carpet 52 is relatively large, it is troublesome to insert the paper, etc., one by one, and the paper removed in the assembling step Post-processing etc. are bothered.

In view of the above background, it is an object of the present invention to provide a vehicle carpet having a structure in which chip waste does not adhere to the other carpet even when the carpets are stacked, and a method for manufacturing the same.

[0008]

In order to achieve the above object, the present invention provides a vehicle carpet in which an insulator made of chip urethane is integrally laminated on the back surface of a backed carpet, and the back surface of the insulator is provided on the back surface of the insulator. It was adhered and had a relatively larger lining than the insulator, and the insulator was sandwiched between the lining and the back surface of the backed carpet. Further, the method of the present invention is a method for producing a vehicle carpet in which an insulator made of chip urethane and a lining are laminated on the back surface of a carpet that has been subjected to a backing treatment, wherein the lining is relatively larger than the insulator. After using, it is integrated with the back of the insulator, then the insulator with the lining,
Place the lining in the molding die so that the lining is located below, and with the peripheral part of this lining locked to the positioning pins provided on the molding die side, place the backed carpet on the insulator. They are stacked and compression molded integrally.

[0009]

According to the above vehicle carpet, when the carpets are stacked, the insulator is not in contact with the carpet surface of the other party, and the lining is in contact with the other carpet surface, and the chips of the insulators are scraps. No longer sticking to and soiling the carpet surface.

Further, according to the manufacturing method of the present invention, after the lining is integrated with the back surface of the insulator, the lining-equipped insulator is arranged so that the lining is located below when arranging it in the molding die. And, the peripheral portion of the lining is locked to the positioning pin on the molding die side, and the carpet after the backing process is stacked on it and compression-molded integrally, so that the insulator is not displaced during pressure molding, The carpet is obtained as designed.

[0011]

Embodiments of the present invention will be described in detail below with reference to the drawings. 3 is an overall perspective view showing an embodiment of the carpet according to the present invention, and FIG. 4 is an enlarged sectional view taken along the line AA of FIG. 3 and 4, the carpet 1
Is a structure in which a loop pile 2 is formed, a back surface of the backing material 3 is coated with a thermoplastic synthetic resin, and an insulator 4 made of chip urethane and a lining 5 are attached to the back surface of the backing material 3. It is made as a three-dimensional one-piece object according to the floor shape by the mold. Nonwoven fabric is used for the lining 5, but other inexpensive materials may be used. The lining 5 is the insulator 4
Which is relatively larger than the backing material 3
Insulator 4 is sandwiched between and.

Therefore, even if a plurality of the carpets 1 are stacked after being molded, the carpet 1 on the lower side and the carpet 1 on the upper side are placed above the surface of the loop pile 2 of the lower side carpet 1 as shown in FIG. Since the linings 5 of the carpet 1 are stacked in contact with each other, the insulator 4 and the loop pile 2 are not stacked in direct contact as in the conventional structure of FIG. It is possible to eliminate problems such as adhesion to the surface of the lower carpet 1. As a result, the work of interposing the paper or the like between the carpets 1 at the time of stacking and the post-processing of the paper removed in the assembling process, which are performed in the conventional structure, are not required.

1 and 2 show the carpet 1 as described above.
2 schematically shows the manufacturing method of. This molding die includes a lower die 11 and an upper die 12, and the lower die 11 has a plurality of positioning pins 13 scattered along the outer periphery (only one positioning pin 13 is shown in the drawing. Although only shown, a plurality of them are actually provided. The original carpet C before the insulator 4 is integrated is produced in the same manner as the conventional one. The insulator 4 is made of chip urethane, and the lining 5 is prepared to be relatively large with respect to the insulator 4.

The insulator 4 is molded into a predetermined floor shape by using a dedicated molding die, and the lining 5 is integrally attached during this molding. Specifically, after the lining 5 is placed in the lower mold of the molding die, the tip urethane material (the tip mixed with the binder) prepared for the insulator 4 is put on the lining 5 under predetermined conditions. When compression molding is performed below, the insulator 4 having a predetermined shape is formed, and at the same time, the backing 5 is integrally attached to the back surface thereof. The upper mold 12 is raised, and the insulator 4 with the lining 5 is taken out from the molding mold.

Next, the insulator 4 with the lining 5 is integrated with the above-mentioned molding die at the same time when the original carpet C is molded. In this case, when arranging the insulator 4 with the lining 5 in the lower mold 11 as shown in FIG.
It is arranged so that the lining 5 is located below, and the peripheral portion of the lining 5 is locked to the positioning pin 13. After that, the backing material is heated and softened.
Placed on top, and from this set state, the upper die 12 as shown in FIG.
When the carpet original fabric C is formed into a predetermined floor shape and is compressed and molded under predetermined conditions, at the same time, an insulator 4 with a lining 5 is integrated on the back surface thereof.
Will be the product of.

As described above, when the original carpet C is compression-molded and the insulator 4 with the lining 5 is integrated at the same time, the workability is improved and the positioning pin 13 is provided.
Since the insulator 4 is held at the fixed position of the molding die by the lining 5 that is locked to the insulator 4, the insulator 4 is not displaced with respect to the carpet 1, and the insulator 4 can be integrated accurately.

[0017]

As described above, since the vehicle carpet according to the present invention has a relatively large lining on the back surface of the insulator made of chip urethane, when the carpets are piled up, the lower side is covered. The top insulator is not in contact with the carpet surface, but the lining is in contact with it. As a result, chips of insulators do not adhere to and stain the carpet surface of the other party, and the handling becomes easier.

Further, according to the manufacturing method of the present invention, an insulator with a lining can be integrated at the same time as the compression molding of the carpet, and the insulator is not displaced, so that a product as designed can be easily obtained.

[Brief description of drawings]

FIG. 1 is a schematic diagram for explaining a method for manufacturing a vehicle carpet according to the present invention.

FIG. 2 is a schematic view showing a molding process for explaining the manufacturing method.

FIG. 3 is a perspective view showing a vehicle carpet according to the present invention.

FIG. 4 is an enlarged sectional view taken along line AA of FIG.

FIG. 5 is a cross-sectional view showing a main part of the carpet of the present invention in a stacked state.

FIG. 6 is a perspective view showing a conventional vehicle carpet.

7 is an enlarged cross-sectional view taken along line BB of FIG.

FIG. 8 is a cross-sectional view showing a main part of a conventional carpet in a stacked state.

[Explanation of symbols]

 1 Carpet 3 Backing Material 4 Insulator 5 Lining 11 Lower Die 12 Upper Die 13 Positioning Pin C Carpet Raw Fabric (Carpet Before Forming)

Claims (2)

[Claims] 1. A vehicle carpet in which an insulator made of chip urethane is integrally laminated on a back surface of a backed carpet, which has a lining relatively larger than that of the insulator attached to the back surface of the insulator. However, the vehicle carpet is characterized in that the insulator is sandwiched between the lining and the back surface of the backed carpet. 2. A method for manufacturing a vehicle carpet in which an insulator made of chip urethane and a lining are laminated on a back surface of a backed carpet, wherein the lining is relatively larger than the insulator. , After the insulator is integrated with the back surface of the insulator, the insulator with the lining is placed in the molding die so that the lining is located below, and the peripheral portion of this lining is a positioning pin provided on the molding die side. A method for manufacturing a vehicle carpet, characterized in that the carpet after the backing treatment is stacked on the insulator in a state of being locked to and is integrally compression-molded.