JPH0692171A - Automobile floor carpet and its manufacture - Google Patents

Abstract

PURPOSE:To improve the productivity of an automobile floor carpet by fusing the high melting point resin layer of the two-layer laminate sheet containing the filler where the melting point is different to the rear surface of the fiber layer. CONSTITUTION:Two-layer laminate sheets 2, 3 extruded from a two-layer common extrusion T die and containing 0-80wt.% of filler where the melting point is different between them are applied to the rear surface of a fiber layer 1 while directing the high melting point side to the fiber layer 1. Then, the resin side is immediately faced toward the surface where a cushon layer 4 is set to the specified position of either die, and the cold extrusion forming is made between the upper and the lower dies, and at the same time, the cushon layer 4 is fused. The post-working such as cutting of the outer circumference is executed, and the desired automobile floor carpet is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile floor carpet and is characterized by improving productivity.

[0002]

2. Description of the Related Art Conventionally, a carpet formed by melt-coating a resin such as polyethylene, ethylene / vinyl acetate on the back surface of a fiber layer with an extruder equipped with a T-die is cut into a predetermined length, and the resin is heated and melted in a heating furnace in advance. If necessary, cold pressing is performed between the upper and lower molds with the resin layer side of the heating carpet facing the surface where the cushion layer is mounted in the predetermined position, and the cushion layer is welded at the same time as molding, and then post-processing such as outer peripheral cutting is performed. It is used as an automobile floor carpet.

[0003]

In the conventional case, it takes time to heat and melt the resin on the back surface of the carpet and time to cool the resin heated by cold pressing, which makes it difficult to improve productivity. Has become. When the temperature of the heating furnace is raised to increase productivity, the phenomenon such as partial burning or large shrinkage of the carpet peripheral area easily occurs, and if the cooling time is shortened, the temperature of the molded product taken out of the mold will increase. Since it is expensive, it is deformed due to subsequent stacking of intermediate products and becomes a defective product. The present invention aims to produce a product without such quality defects with high productivity.

[0004]

An automobile floor carpet in which a two-layer laminate sheet comprising a high melting point layer and a low melting point layer containing 0 to 80% by weight of a filler is formed by welding a high melting point resin layer to the back surface of a fiber layer. By doing so, the purpose could be achieved. Its manufacturing method is two-layer coextrusion T
A two-layer laminated sheet with different melting points extruded from a die is coated on the back side of the fiber layer with the high melting point side facing it, and immediately the resin surface is directed to the surface on which the cushion layer has been installed in a certain position on one of the molds. The cold pressing is performed between the upper and lower molds, the cushion layer is welded at the same time as the molding, and then the outer peripheral cutting and other post-processing are performed to obtain a product.

The high melting point resin needs to have a melting point lower than that of the fibers constituting the fiber layer, and preferable resins are polypropylene, polyethylene and the like. The low-melting point resin has a lower melting point than the high-melting point resin, and when polypropylene is used as the high-melting point resin, polyethylene, ethylene-vinyl acetate, or ethylene-propylene resin can be selected and used as the low-melting point resin. When polyethylene is used as the high melting point resin, ethylene / vinyl acetate resin, ethylene / ethyl acrylate resin, etc. are used as the low melting point resin.
These resins can be mixed with fillers, resins for dispersion or oils, colorants, stabilizers, lubricants, and the like. If a filler is added, the areal density can be improved at low cost and the sound insulation of the carpet can be improved. Can be improved. As the filler, calcium carbonate, barium sulfate,
Inorganic fillers such as talc and titanium oxide and organic fillers such as fibers and pulp can be used. If the blending ratio exceeds 80% by weight, the resin layer becomes brittle and the molded product is cracked, which is not preferable.

As the fiber layer, there is used a tufted carpet raw machine in which pile yarns are tufted on a base cloth, and a needle carpet raw machine in which synthetic fiber webs are laminated and needling. Fiber cushion, chip urethane, molded urethane foam, etc. are used for the cushion layer.

The reason why the composite resin layer of the high melting point resin and the low melting point resin is used is to shorten the pressing time. Further, the high melting point resin surface is directed toward the fiber layer side and the low melting point resin layer is directed toward the cushion layer side because the low melting point resin is preferable for welding the cushion layer. High melting point resin is directly coated on the back surface of the raw material and pressed, so even high melting point resins can be welded. This is because according to this method, heating in a heating furnace is omitted and productivity is improved.

The fact that the cushion layer is set in any one of the molds means that the cushion layer is set in the mold having the convex portion in the front-rear direction at the center of the mold. If it is a mold, it means to set it in the upper mold.

[0009]

Example 1 A polyester spunbond base fabric of 120 g / m ² and a nylon pile yarn of 1600 d / 168 f were used.
Tufting was performed by tufting to / 10 G, 56 st / 10 cm, and 7 mm length to obtain a tufted carpet raw machine. Polypropylene 300g / m ² Polyethylene 300g on the back of this product
/ M ² two-layer sheet is extruded from a T-die and coated, and immediately after the urethane chip cushion layer is set, cold pressing is performed between the upper mold and the lower mold to form the front fiber layer and the back cushion layer at the same time as the molding. . Then, the outer peripheral cutting and other post-processing were carried out to obtain an automobile floor carpet. The surface pressing time can be 15 seconds and the resin coating pressing molding time can be 25 seconds. In contrast to this, the conventional method requires a heating time of 50 seconds and a pressing molding time of 60 seconds. As the product, a product having rigidity and good shape retention was obtained as compared with the conventional polyethylene of 600 g / m ² .

[0010]

Example 2 70% by weight of 10d polypropylene cotton and 1
30% by weight of 2d polyester cotton is mixed and opened with an opener, a card is used as a fleece, and the fleece is folded and laminated to make a web of 350 g / m ² and needle punched to form a fiber aggregate. Punch at 3 to form looped naps on the surface 3
A greige of 20 g / m ² was obtained. On the back side of this product, from the two-layer extrusion T-die, on the fiber side, polypropylene 200 g / m ²
The outer surface is covered with a sheet of 200 g / m ² of ethylene / vinyl acetate resin having a vinyl acetate content of 20%, and immediately after that, the fiber felt is set and pressure-molded between the upper and lower molds to mold on both sides of the resin. A molded product with the needle greige and fiber felt welded was obtained. Peripheral cutting was performed on the product itself to obtain an automobile floor carpet. In terms of quality, this product had better adhesion to the panel than the conventional one. In terms of productivity, it can be molded in 15 seconds for greige molding and 25 seconds for coating and pressing of composite resin.
Second, the productivity could be greatly improved compared with the press molding time of 60 seconds.

[0011]

According to the present invention, the productivity of automobile floor carpets can be improved. Also, the adhesion to the panel could be improved.

[Brief description of drawings]

FIG. 1 is a partial sectional view of an automobile floor carpet.

[Explanation of symbols]

 1 Carpet greige 2 High melting point resin layer 3 Low melting point resin layer 4 Cushion layer

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Claims (2)

[Claims] 1. An automobile floor carpet in which a high melting point resin layer of a two-layer laminate sheet containing 0 to 80% by weight of a filler and having different melting points is welded to the back surface of a fiber layer and molded. 2. A two-layer laminate sheet having different melting points each containing a filler of 0 to 80% by weight is coated from a two-layer coextrusion T-die on the back surface of the fiber layer with its high melting point side facing, and immediately the cushion layer is formed. Automotive floor consisting of cold pressing between the upper and lower molds with the resin side facing the surface set in a certain position of one of the molds, welding of the cushion layer simultaneously with molding, and subsequent post-processing such as peripheral cutting. Carpet manufacturing method.