JPS584642A - Carpet for automobile - Google Patents

Abstract

PURPOSE:To increase strength against exfoliation and reduce occurrences of position misalignments or wrinkles, by solidifying and molding a filling material, consisting of crushed elements, to a plate shaped unit with a binder and gluing the plate shaped unit to the rear side of a carpet through a back coat of thermo-plastic resin material. CONSTITUTION:A plate shaped unit 5, previously solidified and molded with a filling material, consisting of crushed elements 5a of urethane or polyvinyl chloride system quality, by a thermo-setting resin binder 5b of phenol resin or the like, and a carpet main unit 2, laminated with a back coat 3, are heated and molded under pressure. Then the back coat 3 is softened, and the plate shaped unit 5 can be glued to the reverse side of the carpet main unit 2. In this way, the carpet main unit 2, back coat 3 and the plate shaped unit 5, consisting of the crushed elements 5a and the binder 5b, are formed to a layer-built unit, and a carpet for an automobile can be obtained.

Description

[Detailed description of the invention] This invention relates to automobile carpets.

BACKGROUND OF THE INVENTION Conventional carpets for automobiles include butterflies, such as those shown in FIGS. 1 to 3.

In these figures, reference numeral 2 denotes a carpet body, and 3 a back coat. This back coat 3 is made of a thermoplastic resin material made of polyethylene, and is laminated in advance on the back side of the carpet body 2. Reference numeral 4 denotes a fiber layered body, in which fibers 41 having a thickness of 20 denier ms are oriented in the same direction as the surface direction of the layered body 40 and bonded with a binder of thermoplastic resin 4b. has been done. The fiber layered body 4 has a basis weight (the weight of the entire fiber waste material equivalent to a unit area) of 0.6 to 1.2 V♂.

Then, the carpet body 2 on which the back coat 3 is laminated and the fiber layered body 4 are pressure-molded in a predetermined mold under heating to form an automobile carpet l that fits the shape of the automobile floor surface. There is.

However, in such a conventional automobile carpet, the backing fiber layer 4 has a fiber length of $14m.
The fibers 4a are oriented in the same direction as the plane of the scissor fiber layered body 4 and are bonded with a thermoplastic resin binder, so when a force in a direction perpendicular to the plane is applied, the fibers 4a
It is easy to peel off at this part and has relatively low peel strength. Since the fiber itself has no rigidity, the carpet as a whole has low rigidity. For this reason, when a large vacuum cleaner or the like is used to clean the carpet, delamination occurs and the carpet floats, and when you step on it with your foot, it tends to shift or wrinkle. there were. The low rigidity can be improved by increasing the basis weight, but there is a problem in that such measures result in increased costs.

This invention was made by focusing on the problems of the conventional carpet.A plate-shaped body made by solidifying and molding a filler made of crushed pieces with a binder is coated on the back side of the carpet body with a back coat made of a thermosetting resin material. It is intended to solve the above problems.

The present invention will be explained below based on the drawings.

In each of the figures from FIG. 4 onward, the K of 4, which is the same or equivalent to the members in FIGS. 1 to 3, is designated by the same reference numerals as above, and a redundant explanation will be omitted.

In this invention, a plate-shaped body (chip molded body) 5 which has been assimilatedly molded in advance with a filler made of crushed pieces 51 using a binder 5b is attached to the back surface of the carpet body 2 with a back coat 3. A laminate of the coat 3 and the plate-like body 5 constitutes an automobile car vera 11.

As the crushed pieces 5a, a suitable member or scrap material is pulverized to a size of approximately several square centimeters. The materials used are urethane, urethane and pvc (fi).
(vinyl chloride) film, urethane and fabric laminate, P-V-
A single C film, a single fabric, etc. are used, and among these, urethane and PV/C based materials are used as the main materials.

Further, as the binder 5b, for example, a thermosetting resin made of phenol resin is used. The plate-shaped body 6 is, for example, about 5 m of crushed pieces of about 80 we.

Approximately 20 mm of binder 5b and binder K are preformed in a predetermined mold into a shape that fits the shape of the floor surface of an automobile. In consideration of moldability and the like, the plate-like body 5 may be divided into an appropriate number of pieces as shown in FIG. 4, or may be formed into a single groove.

As described above, the plate-shaped body 5 is formed such that the individual pieces 5a are bound together by the binder 5b, since about 80 wt- is occupied by the pieces 5. Therefore, the peel strength and rigidity of the plate-like body δ are substantially influenced by the characteristics of the urethane and PVC-based material used for the crushed pieces 5a. For example, for peel strength [K], as shown in Fig. 6, cut out a test piece with a width t of 25 m, fix one part 6 m with a chuck, etc., and fix the other part 6 b with 50 cm/width t.
When calculating the load W when the layered material 4 is pulled at the speed of the treadmill, it is 0 for the conventional fiber layered material 4 shown in FIG.
．． 08 to 0.1514, whereas the plate-shaped body 5 had a strength of 0.4 to 0.651, which is about four times as strong as that of the conventional one.

On the other hand, the carpet body 2 uses a tufted carpet body and a needling carpet body in the front, and the thickness of the back coat 3 laminated thereto is −0.2 to 0.
．． It is said to be about 6-.

Then, as shown in FIG. 7, a round plate-shaped body 5 previously formed into a predetermined shape was placed on the lower ff 17b of the mold consisting of the upper @Tab and the lower swing 7b, and the back coat 3 was laminated thereon. The carpet body 2 is positioned, heated to an appropriate temperature, and pressure-molded. At this time, the dust coat 3 is softened by heating, and the plate-shaped body 5 is adhered to the back surface of the carpet body 2, thereby forming the automobile carpet 11 integrated in a laminated manner as described above. As an example, the weight of the plate-shaped body 50 in this automobile carpet 11 is 0.5 to 50.
It is said to be 2.0kf/11.

Next, the effect will be explained.

Fragments 5 mainly made of urethane and P-V-C materials
The peel strength and rigidity of the automobile car bella (11) are increased to the required level by the plate-like body (5) formed by bonding the filler material made of tortoise with the binder (5b).

Therefore, even if a large vacuum cleaner or the like is used for cleaning, delamination will not occur, and lifting of the carpet will not occur. Even if a person with the weight of 1 and Kanashi steps on it with his/her foot, "wrinkles" will not occur during the positional shift.

Next, FIG. 8 shows another embodiment of the present invention.

In this other embodiment, the carpet body 2a has a basis weight of 0.
It uses a non-woven fabric body of 15 to 0.71 #/l/.

The other materials used and the structure are almost the same as in the previous embodiment. Further, the effects of peeling resistance and the like due to increased peel strength and rigidity are almost the same as in the above embodiments.

In each of the above embodiments, a thermosetting resin was used as the binder 5b of the plate-shaped body 5, but in this invention, a Creta/based adhesive or a thermoplastic resin such as polyethylene may be used instead.

When a thermoplastic resin is used as the binder 5b, the plate-like body 5 does not need to be solidified and molded in advance into a shape that fits the shape of the floor surface of the automobile, and may simply be solidified and molded into a flat plate shape. . A plate-shaped body 5b using a thermoplastic resin as a binder 5b is formed into a predetermined shape so as to fit the shape of the floor surface during heat molding using a molding WK.

As detailed above, according to issue #84, a plate-shaped body made by solidifying and molding the filler material from the debris with a binder is pasted on the back side of the carpet body with a back coat made of thermoplastic resin material. The peel strength and rigidity have been increased to the required level, so even if you use a large vacuum cleaner etc. when cleaning the carpet, there will be no delamination or peeling of the carpet, and there will be no problem. This has the effect that when someone weighing a lot of weight steps on the product, there will be no misalignment or wrinkles.

Furthermore, suitable members and scrap materials can be used as the material for forming the plate-shaped body, and even if the plate-shaped body is made to have the same amount of weight as #1 compared to the conventional one, the rigidity can be improved as described above. Therefore, it is possible to provide an extremely economical automobile carpet that saves resources.

Further, according to another embodiment in which a nonwoven fabric is used as the carpet body, in addition to the above-mentioned common effects, it is possible to provide an even cheaper plain needle type automobile carpet.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing a conventional automobile carpet, 82
The figure is a sectional view taken along the OT-1 line of the same carpet. 3wJ is a partially enlarged view of the 1 m2 diagram, FIG. 4 is a sectional view similar to FIG.
The figure is a perspective view showing an example of a peel strength test of an automobile carpet, FIG. 7 is a front view showing an example of the pressure molding method for an automobile carpet shown in FIG. 4, and FIG. 8 is another embodiment of the present invention. FIG. 2 is a cross-sectional view similar to FIG. 2.2m...carpet body, 3...back coat. 5... Plate-shaped body, 5 Otori... Crushed pieces, 5b... Binder. 11, u... Car carpet Fig. 1 Fig. 2 Fig. 4 Fig. 11 Fig. 5 1 Fig. 6 Fig. 7

Claims (1)

[Claims] A carpet for an automobile, characterized in that a plate-shaped body made by solidifying and molding a filler made of crushed pieces with a binder is adhered to the back side of a carpet body with a back coat made of a thermoplastic resin material.