JPH0899574A - Automobile carpeting body and manufacture thereof - Google Patents

Abstract

PURPOSE: To improve the wear strength of the surface and the separation strength of a back face cushion by bonding a lower layer formed by mixing high fusing point fiber and/or natural fiber and low fusing point fiber, and an upper layer formed by mixing polyester colored cotton and low fusing point fiber by mutual entanglement and the welding of low fusing point fiber. CONSTITUTION: This automobile carpeting body has a lower layer formed by mixing 40-80 pts.wt. of high fusing point fiber such as polyester and/or natural fiber and 20-60 pts.wt. of low fusing point fiber such as polypropylene, and an upper layer formed by mixing 70-90 pts.wt. of polyester colored cotton and 10-30 pts.wt. of low fusing point fiber. Fiber compound material formed by bonding the upper and lower layers by the mutual entanglement of fiber and the welding of low fusing point fiber is fabricated to obtain the carpeting body having side sill parts 1R, 1L, a dash side end part 2 and a rear end part 3 and further having a cutout part 4, a bored part and cross member parts 5R, 5L formed thin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile floor covering. The feature is that the backing resin, the binder resin, and the cushioning material are not lined, and yet the necessary functions are provided.

[0002]

2. Description of the Related Art Conventionally, as a floor covering without a backing resin or a binder resin, a plain type needle carpet for forming a surface layer is laminated on a non-woven web made of a mixed fiber of a high melting point fiber and a fiber binder, A multi-layer carpet that can be formed by needle-punching from the surface side to entangle the fibers with each other, then heat to melt only the fiber binder to fix the fibers and integrate the surface plain carpet and the backing web. Have been proposed.

In automobile floor coverings, a cushioning material is used by being heat-welded or adhered to the back surface of the floor covering. A fiber felt is generally used as the cushion material. In addition, there are those made of urethane chips, polyurethane made by injection foaming, and the like, each of which is a separate component different from the upper layer and fixed to the back surface of the floor covering.

[0004]

By the way, in the conventional floor covering, the peel strength of the plain carpet layer for the surface layer is weak, and therefore the abrasion strength is also weak, which is not practical. In addition, if a cushion material, which is a separate component, is fixed to the back surface, peeling often occurs. Therefore, an object of the present invention is to provide an automobile floor covering having a cushioning function which is free from such a problem and which does not cause the cushioning material to peel off. Separately, it was also aimed at improving the cuttability and the punching workability. In addition, the cushioning material, which is a separate component of the related art, is often a flat one, while on the floor surface of an automobile there is unevenness in the beads, so the adhesion of attachment is poor and the material deforms over time so that the surface becomes uneven. Since there is a problem that the external appearance quality deteriorates, we aimed to solve it.

[0005]

As a result of studies for solving the above-mentioned problems, "high melting point fibers and / or natural fibers 40
-80 parts by weight, a lower layer containing 20-60 parts by weight of low melting point fibers, 70-90 parts by weight of polyester colored cotton, and an upper layer containing 10-30 parts by weight of low melting point fibers are entangled with each other and have a low melting point. It is possible to solve the intended improvement of surface wear strength and improvement of peeling strength of cushioning material by making it an automobile floor covering in which a fiber composite body formed by fusion of fibers is molded and processed. did it. Furthermore, the main purpose is to improve the surface abrasion strength and the peeling strength of the cushioning material, by saying, "The floor covering for automobiles is formed so that the back surface of the composite can be laid closely on the unevenness of the floor surface of the automobile." It was possible to improve the appearance quality and the mounting adhesion. Furthermore, “The side sills (1R, 1L), dash side edges (2), rear rear (3), notch (4), perforations and cross members (5R, 5L) of automobile floor coverings are thin. It was possible to improve the cutability and the punching workability, which are other purposes, by using the "automobile floor covering". Specifically, a molded article with good heat resistance could be obtained by using "a floor covering for an automobile in which the high melting point fiber is a polyester fiber and the low melting point fiber is a polypropylene fiber". Further, the cost can be reduced by using the "bedding material for automobiles in which the lower layer high melting point fiber and / or natural fiber is anti-wool". "The overall basis weight is 600-1
The weight of the lower layer is 500-1300 g / m ² at 500 g / m ^2.
It was possible to obtain a practical automobile floor covering by using "No. ² automobile floor covering".

Here, the high melting point fibers are polyester, nylon, acrylic fibers and the like, and the natural fibers are mainly cotton and wool. The low-melting point fiber serves as a binder fiber, and preferably has a melting point lower than that of the high-melting point fiber by at least 40 ° C. or more. For example, polypropylene, polyethylene, ethylene-propylene copolymer,
The low melting point polyester, the low melting point polyamide fiber, etc. are applicable.

If the blending ratio of the low melting point fiber in the lower layer is 20% or less, the weldability with the upper layer becomes insufficient and the abrasion strength of the surface layer becomes unacceptable, which is not preferable. When it is 60% or more, the cushioning property of the lower cushion portion is deteriorated, which is not preferable. If the blending ratio of the low melting point fibers in the upper layer is 10% by weight or less, the surface abrasion strength is unacceptable. When it is 30% or more, the surface of the molded product is markedly shiny, which is not preferable in appearance.
The preferred range is 10-30% by weight.

Next, if the weight of the floor covering is 700 g / m ² or less, it fails in terms of strength and the cushioning property of the cushion portion becomes insufficient. If it is 1500 g / m ² or more, there is a problem in that it becomes unnecessary to synthesize a portion having a high degree of compression, the mountability to a vehicle is deteriorated, the weight of the vehicle body becomes heavy, and the cost becomes high.

Next, regarding the manufacturing method, "high melting point fibers and / or
Or 40-80 parts by weight of natural fiber, 20-6 of low melting point fiber
7 parts by weight of cotton is mixed to form a web on a conveyor through a web former, and polyester colored cotton 7 is formed on the web.
A fleece formed by blending 0-90 parts by weight and 10-30 parts by weight of low-melting point fibers with a mixed cotton card was folded and laminated, and then needle punched from the surface side to obtain a fiber composite. After heating to a temperature at which the low melting point fibers of the fiber composite melt but the high melting point fibers do not melt, the back surface of the fiber composite is cold pressed into a mold with an automobile floor surface with the smooth mold upper surface facing the surface. A method for manufacturing an automobile floor covering, which comprises: The purpose of the present invention is to produce a backing material for automobiles, which has a practical surface wear strength without peeling of the cushion portion without using a backing material and a binder resin, and which has good mounting adhesion. You can Ie 7
The depressions of RB (A), 7RB (B), 6RB (C), etc. correspond to the convex portions of the beads on the floor surface of the car (not shown), and they will be engaged when mounted.

[0010]

The low-melting point fiber serves as a binder fiber by fusing the surrounding high-melting point fiber and the natural fiber by heat fusion, and becomes a fixed state after cooling, and has a function of imparting shape retention and rigidity.
When the low-melting point fiber is also mixed in the upper layer, the high-melting point fiber in the upper layer is welded and the welding with the lower layer is improved, and as a result, it has the function of improving the wear strength of the surface.

During molding, the contact mold surface on the back side is shaped like an automobile floor, and the mold surface on the front side is a smooth flat surface and a curved surface. When the heated multi-layer web is cold pressed, the back surface fits on the mold surface. In the part where the convex part of the lower layer is thick, that part has cushioning properties and the part where another part as a conventional cushion material was fixed is not a separate part but a rigid part under the floor covering It forms a cushioned part.

Still further, the upper mold side sill portion (1R, 1
L), the dash side end portion (2), the rear rear portion (3), the notch portion (4), the perforation portion and the cross member portions (5R, 5L) can be made higher with the lower mold during molding. The spaces between the parts become narrower, so that the molding is pressed to form thin, rigid parts. As a result, the cuttability, the punching workability, and the shape retention are improved.

Next, the manufacturing method will be described with reference to the process chart of FIG. A mixture of high-melting-point fibers and low-melting-point fibers forming a lower layer (11) and opened (12) with a fiber opening machine such as a cylinder opener or a Claiton opener is supplied in a fixed amount from a hopper feeder to obtain a lower layer web (1
Follow step 3). On the other hand, a fleece (24) obtained by carding (23) a mixed fiber obtained by opening (22) a high-melting point fiber and a low-melting point fiber which form an upper layer in a direction perpendicular to that with a cotton (21) opener with a card machine (23) Is folded and laminated on the lower web with a cross layer device to form a laminated web (14), and then the needling (15) is applied from the upper layer side.
To form an integrated web, which is cut (16) into a predetermined size of the floor covering, and then, as a separate step, the cut product is heated (17) by a heating device to melt the low melting point fiber. Immediately cold press molding between molds of a predetermined shape (18)
After that, outer peripheral cutting, notching, perforation processing (19) and the like are performed to manufacture an automobile floor covering.

As another manufacturing method, the needling (1
5) Both ends are gripped and heated (161) by hot air suction in a heating furnace, and then lightly pressed between the rollers (16).
2) After adjusting the thickness, cooling (163) with cold air suction and cutting (16) to a predetermined size are performed in a series of continuous steps, and then as a separate step, an automobile floor covering is manufactured by the above method. be able to.

[0015]

[Example 1] 60 parts by weight of anti-wool of a fabric composed of polyester fibers and natural fibers and 40 parts by weight of polypropylene fiber cotton were mixed (11), and the cotton was opened (12) through a cylinder opener while being supplied in a fixed amount. Are accumulated on a conveyor to produce a web of 700 g / m ² ,
On the other hand, from the direction perpendicular to the flow, 90% by weight of black polyester solution-colored polyester cotton and 10% by weight polypropylene cotton were mixed (2
1) Fleece (24) obtained by opening (22) through a feeder, blender, and cylinder opener, and carding (23) with a card machine is folded and laminated with a cross layer on a web (13) in an amount of 200 g / m ² (20). 14) Then, after passing through a needle room, a needling (15) of 80 times / cm ² is performed from the upper layer surface to integrate the upper and lower layers, and after cutting (16) and heating (17), the polypropylene fibers are melted to form a back surface. The mold contacting with the mold has irregularities in the shape of the floor surface of the automobile, and the mold face contacting with the surface is cold pressed (18) between a mold having a smooth flat surface and a curved surface, and outer peripheral cutting, perforating, etc. 19) Go to make a bedding.

The wear strength of the surface layer of this material is the wear ring H3.
Passed in the 3-4 grade at 1,000 rpm with 8, 1 kg load.
The cushioning of the cushion part is good, the adhesion is good, it is light and the workability of wearing is good.
It was a floor covering with almost no change in shape even after the heat cycle test of four times. In the case where the upper layer was not blended with the low melting point fiber, the abrasion strength was grade 2 and was unacceptable.

[0017]

Example 2 70 parts by weight of the anti-wool cotton used in Example 1 and 30 parts by weight of polypropylene cotton were mixed (11), and the cotton opened (12) through a cylinder opener was accumulated on a conveyor to 900 g / m. ^On the other hand, while manufacturing the web ( ² ) ( ² ), 80 parts by weight of black cotton liquid-colored polyester cotton and 20 parts by weight of polypropylene cotton were mixed (21) from the direction perpendicular to the flow of the web (13) and opened (22) through a feeder, a blender and a cylinder opener. ) Carding with a card machine (2
3) The obtained fleece (24) was folded and laminated with a cross layer on the web (13) in an amount of 300 g / m ² (14).
Then, the upper and lower layers are integrated by performing needling (15) at 80 times / cm ² through the needle room, and then polypropylene cotton is melted (161) by passing hot air at 200 ° C. by a hot air forced penetration furnace while gripping both ends. Lightly compress with a roll, then cool by passing cold air (162)
After that, it was cut into a predetermined size.

This is sandwiched between two hot plates and heated (17)
Then, the mold in contact with the back surface of the remelted fiber multi-layered polypropylene is the mold of Example 1 and the mold on the front surface side is side sills (1R, 1
L), the vicinity of the dash side end portion (2), the rear rear portion (3), the notch portion (4), and the hole processing portion are raised, that is, stress is applied particularly during molding, and the same as in Example 1. Then, press molding, perimeter cutting and perforation processing were carried out to obtain a floor covering.

The abrasion resistance of this product was grade 3-4, and the heat cycle test was also very good. The flat part of the vehicle and the bulging part in the center part in the front-rear direction are thick and have cushioning properties, and the strongly pressed outer peripheral part, notch, hole, etc. are thin and have large rigidity, so cutting and drilling etc. It was a floor covering that was easy, had no fraying, had good adhesion to the floor surface of an automobile, and had good workability.

[0020]

In the present invention, the low-melting-point fiber is blended not only in the lower layer but also in the upper layer, so that the adhesive force between the upper and lower layers can be increased and the surface abrasion strength can be improved. In addition, it can be manufactured at a low cost by using anti-cotton as the lower layer, and in terms of shape, it is possible to form a concavo-convex shape that fits the shape of the car floor surface and to give mounting adhesion, and with good appearance quality We were able to. Furthermore, the flat part and the bulging part in the front-back direction of the central part have cushioning properties due to the lower layer, and the peeling problem that was conventionally attached as a separate part, the management of other parts such as production management and inventory management are deleted, and the cost is reduced. Was obtained.

[Brief description of drawings]

FIG. 1 is a plan perspective view of an automobile floor covering according to the present invention.

FIG. 2 (a) is a sectional view taken along line XX of FIG.

2 (b) is a cross-sectional view taken along line YY in FIG.

FIG. 3 is a manufacturing process diagram of an automobile floor covering of the present invention.

[Explanation of symbols]

 1R 1L Side sill part 2 Bulging part 3 Rear rear part 4 Notch part 5R 5L Cross member part 6R 6L Front floor part 67R 7L Rear floor part

Claims (7)

[Claims] 1. High melting point fibers and / or natural fibers 40-8
0 part by weight, a lower layer containing 20-60 parts by weight of low-melting fibers, 70-90 parts by weight of polyester colored cotton, an upper layer containing 10-30 parts by weight of low-melting fibers are entangled with each other and a low-melting fiber. An automobile flooring in which a fiber composite body bonded by welding is molded and processed. 2. The floor covering for an automobile according to claim 1, wherein the back surface of the fiber composite is molded so that it can be laid in close contact with the unevenness of the floor surface of the automobile. 3. A car sill of claim 1, wherein the side sill portion, the dash side end portion, the rear rear portion, the notch portion, the perforated portion and the cross member portion are thin. Floor covering for automobiles. 4. The automobile floor covering according to claim 1, wherein the high melting point fiber is a polyester fiber and the low melting point fiber is a polypropylene fiber. 5. The automobile floor covering according to any one of claims 1 to 4, wherein the lower melting point fiber and / or the natural fiber is anti-wool. 6. The automotive bedding body according to any one of claims 1 to 5 total basis weight of 600-1500g / ^{m 2} lower basis weight is characterized by a 500-1300g / ^{m 2} . 7. High melting point fibers and / or natural fibers 40-8
0 parts by weight and 20-60 parts by weight of the low melting point fiber are mixed to form a web on a conveyor through a web former.
Fleece formed by mixing 70-90 parts by weight of polyester colored cotton and 10-30 parts by weight of low-melting fiber with mixed cotton carding was folded and laminated thereon, and then needle punched from the surface side to obtain a fiber composite. After heating to a temperature at which the low melting point fibers of the fiber composite melt but the high melting point fibers do not melt, the back surface of the fiber composite is cold pressed into a mold with an automobile floor surface with the smooth mold upper surface facing the surface. A method for manufacturing an automobile floor covering, which comprises: