JP2007276722A - Lightweight floor mat for automobile with sound absorbing effect - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat for an automobile light in weight and excellent in a slip-preventive property and sound absorbing performance. <P>SOLUTION: A slip-preventive fiber sheet with dense short fibers wherein nylon short fibers are flocked on nonwoven fabric constituted of synthetic fibers by flocking (electric flocking) is used on the back surface of the floor mat for the automobile as a slip-preventive layer while using a surface on which the nylon fibers are flocked as an adhesive surface with a floor. A large number of small holes penetrating the floor mat for the automobile are formed. Therefore, the floor mat for the automobile light in weight and excellent in a slip-preventive property and sound absorbing performance can be obtained. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a technique for an automobile floor mat that is used by being placed on a tufted carpet or a needle punched carpet previously laid on the floor of an automobile.

Conventionally, in automobiles, dirt, sand, mud, gravel, or rainwater adhering to shoes, etc., adheres to tufted carpets and needle punch carpets laid on the floor of automobiles, and the interior of automobiles has become dirty. In order to prevent this, an automobile floor mat is laid.

As this automobile floor mat, as disclosed in Patent Document 1, there is known a floor mat made of a surface material such as a carpet and a backing material such as a synthetic resin or rubber that supports the surface material. In such a floor mat, durability is imparted by the backing material, and an anti-slip effect is imparted by providing a large number of protrusions on the backing material.

However, since the anti-slip layer made of synthetic resin or rubber in this conventional floor mat for automobiles is as heavy as 1,200-1,500 g per 1 m ² , the fuel efficiency of the automobile becomes worse when it is placed in the automobile compartment, and as a result As a result, a great load is placed on the environment.

Further, this conventional automobile floor mat is made of synthetic resin or rubber, and has a protrusion on the back surface. When the conventional automobile floor mat is placed on a tufted carpet or needle punched carpet, Then, when a person stepped in, the protrusions got stuck in the pile and worked to stop slipping, but in recent years, high quality is required for the appearance quality of automobile interior materials, the above-mentioned tufted carpet, or Since the needle punch carpet has become a high-density product using thin threads, the protrusions have become difficult to bite. For this reason, a floor mat for an automobile having a synthetic resin or rubber backing is slippery. Further, when the floor mat for an automobile starts to slide, the contact portion with the tufted carpet or the needle punch carpet arranged on the floor becomes Since it tends to be only the apex of the protrusion and the contact area is reduced, slippage is promoted on the contrary, and there is a possibility of causing an accident.

On the other hand, in recent years, quietness in automobile interiors has been highly demanded, and various attempts have been made. One of them is improvement of the sound absorption effect in the automobile floor mat itself. However, in the automobile floor mat having the above-described conventional structure, a resin layer is provided on the back surface side, and this resin layer absorbs sound although it has a characteristic of reflecting sound from outside the vehicle. The characteristics are low. Therefore, it does not contribute much to the quietness in the interior of an automobile.
Japanese Examined Patent Publication No. 4-856

The present invention was made in order to solve the above-described problem of the weight that imposes a load on the environment and the slipperiness that leads to accidents, and furthermore, the sound absorption that impairs the quietness in the automobile interior, and is lightweight and anti-slip. An object of the present invention is to provide an automotive floor mat that is excellent in sound absorption and environmentally friendly.

In order to achieve the above object, the present invention provides the following means.

[1] An automotive floor mat comprising an upper carpet, an anti-slip fiber sheet, and an adhesive layer, and the dense anti-slip fiber group in which nylon short fibers are planted on a base layer made of a synthetic fiber nonwoven fabric. A floor mat for an automobile comprising a fiber structure, wherein a pile surface of the upper carpet and a surface on which the nylon short fibers of the non-slip fiber sheet are planted are bonded to each other with an adhesive layer.

[2] A ratio of 80 to 120 g / m ² of short fibers made of synthetic fiber by applying a flocking adhesive to a non-woven fabric having a weight of 80 to 120 g / m ² , wherein the non-slip fiber sheet is made of polyester fiber. In the preceding item [1], which is a non-slip fiber sheet having a dense flocked short fiber group planted by flocking process (electric flocking process) and having a total weight of 160 to 240 g / m ^2. ] The floor mat for automobiles described.

[3] A short fiber made of nylon having a length of 0.4 to 1.0 mm and a thickness of 0.7 to 2.0 dtex, wherein the short fiber to be flocked to the non-slip fiber sheet by flocking (electrical flocking) The floor mat for an automobile according to the above item [1] or [2].

[4] After the anti-slip fiber sheet in which the upper carpet and the flocked short fiber group are planted are bonded together by the adhesive layer, the anti-slip fiber sheet is used from the anti-slip fiber sheet side using a needle-like member. From the side, a large number of small holes are formed through the upper carpet and the non-slip fiber sheet, and the air permeability in the thickness direction of the entire automobile floor mat is 1 to 50 (cm 3 / cm 2 · sec) The automobile floor mat according to any one of [1] to [3] above.

[5] The automobile floor according to any one of [1] to [4] above, wherein the adhesive layer for bonding the upper carpet and the anti-slip fiber sheet is a polyethylene resin film of 100 to 200 g / m ^2. mat.

Flocking process (electric flocking process) is the surface of a textile product that is planted by applying an adhesive to a base layer made of woven or non-woven fabric, and using static electricity to adsorb short fibers called piles vertically. Finishing process.

In this specification, “air permeability” is the air permeability measured by the A method of 827.1 of JISL 1096-1999.

According to the invention of [1], tufted carpets, needle punched carpets, etc. that have been pre-installed on the floor of the automobile by the group of dense short fibers planted with the non-slip fiber sheet constituting the automobile floor mat of the present invention. The floor mat for automobiles has an improved frictional resistance with the fibers constituting and improved slip prevention.

According to the invention of [2], the automobile floor mat of the present invention comprises a lightweight non-slip fiber sheet having a weight of 160 to 240 g / m ^{2 made} of fibers instead of a synthetic resin or rubber having a heavy anti-slip layer. By using it, it is possible to make a car floor mat that is much lighter than conventional floor mats. Further, by reducing the weight, the fuel efficiency of the automobile is not deteriorated, and the automobile floor mat has a low environmental load.

According to the invention of [3], the short fibers implanted by the flocking process (electric flocking process) on the non-slip fiber sheet have a length of 0.4 to 1.0 mm and a thickness of 0.7 to 2.0 dtex. By using short fibers made of nylon, it can be manufactured with existing flocking machines, and the short fibers themselves will not bend and become a rigid raised state, resulting in an automotive floor mat with improved anti-slip properties. .

According to the invention of [4], after the upper carpet and the anti-slip fiber sheet in which the flocked short fiber group is planted are bonded together by the adhesive layer, the needle-like member is used from the anti-slip fiber sheet side. In addition, by forming a large number of small holes penetrating the upper carpet and the non-slip fiber sheet from the non-slip fiber sheet side, the small holes become sound absorption holes, and the overall thickness of the automobile floor mat The air permeability in the direction can be ensured to 1 to 50 (cm ³ / cm ² · sec). As a result, the automobile floor mat of the present invention exhibits excellent sound absorption, and can provide quietness in the automobile compartment.

According to the invention of [5], since the adhesive layer constituting the automobile floor mat of the present invention is a polyethylene resin film of 100 to 200 g / m ² , the air permeability in the thickness direction of the entire automobile floor mat is increased. 1 to 50 (cm ³ / cm ² · sec) can be secured. As a result, the automobile floor mat of the present invention exhibits excellent sound absorption, and can provide quietness in the automobile compartment.

Hereinafter, an embodiment of an automobile floor mat according to the present invention will be described with reference to the drawings. The automobile floor mat of the present embodiment is an automobile floor mat that is used by being placed on a tufted carpet or a needle punched carpet previously laid on the floor of the automobile. FIG. 1 is a schematic cross-sectional view showing an enlarged part of the automobile floor mat of the present embodiment. (1) is an upper carpet, (2) is an adhesive layer, (3) is a base layer, (4) is a flocking adhesive layer, (5) is a short fiber group, and (6) is a non-slip fiber sheet.

The upper carpet (1) may be a tufted carpet woven by a tufted carpet machine, tsutsutsu, hook carpet, wilton carpet, akisminster carpet, needle punch carpet or the like. Ted carpet is preferred.

The pile of the upper carpet (1) can be made of polyester, nylon, polypropylene or the like.

In order to prevent the fibers from falling off in the upper carpet (1), a latex layer such as styrene-butadiene rubber is provided on the lower surface of the upper carpet (1) to fix the fibers and prevent the pile from coming off.

Moreover, as a pile of the short fiber group (5) of the non-slip fiber sheet, nylon, polypropylene, or the like can be used, but it is preferable to use a nylon short fiber because it uses static electricity.

The nylon short fiber has a length of 0.4 to 1.0 mm and a thickness of 0.7 to 2.0 dtex nylon fiber, and the combined effect of the length and thickness of the short fiber, The dense short fiber group of the anti-slip fiber sheet (6) is in a raised napped state, and the automobile floor mat according to the present invention is placed on the tufted carpet or needle punch carpet previously provided on the floor of the automobile. When the stop fiber sheet (6) is disposed so as to abut, the tip of the short fiber group is caught on the piles constituting the tufted carpet, needle punch carpet, etc., and as a result, the anti-slip property is improved. To do.

If the length of the nylon short fiber is less than 0.4 mm, the pile of the tufted carpet and the needle punched carpet provided in advance on the floor of the automobile cannot be put in, and a sufficient anti-slip effect cannot be obtained. . In addition, when the length exceeds 1.0 mm and the thickness is less than 0.7 dtex, the short fibers themselves cannot be bent to obtain a sufficient anti-slip effect, and further exceeds 2.0 dtex. In the case of the thickness, the contact area with piles such as tufted carpets and needle punch carpets provided in advance on the floor of the automobile is reduced, and a sufficient anti-slip effect cannot be obtained.

The base layer (3) for planting the short fibers of the non-slip fiber sheet (6) can be made of woven or non-woven fabric such as polyester fiber, nylon fiber or polypropylene fiber. Preferably, it is a nonwoven fabric which consists of polyester fiber which has heat resistance and is dimensionally stable.

Moreover, the structure which has many space | gap by making the weight of the nonwoven fabric which consists of the said polyester fiber into 80-120 g / m < ² > adds the heat | fever and pressure at the time of bonding the said upper-layer carpet and the said non-slip fiber sheet. In addition, the air permeability in the thickness direction of the entire automobile floor mat can be secured to 1 to 50 (cm ³ / cm ² · sec).

The non-slip fiber sheet (6) is constituted by flocking the nylon short fibers by flocking (electric flocking) on a base layer (3) made of polyester fibers. Density of bristles is preferably a rate of 80 to 120 / ^{m 2,} not trivial is denseness is less than 80 g / ^{m 2,} can not be obtained a sufficient effect of slip, too dense exceeds 120 g / ^{m 2,} of a motor vehicle Tufted carpet and needle punched carpet piled in advance on the floor cannot be put in hard, and a sufficient anti-slip effect cannot be obtained.

The non-slip fiber sheet (6) includes the non-slip fiber sheet (6) in which the nylon short fibers are planted by flocking (electric flocking) on the base layer (3) made of polyester fiber and the upper carpet ( 1) is bonded with the adhesive layer, and then the upper carpet (from the non-slip fiber sheet is spaced from the non-slip fiber sheet at an interval of about 5 mm by using a needle having a diameter of about 2 mm from the non-slip fiber sheet side. A number of small holes are made on the entire surface by applying 1). In this sound absorption hole, in addition to the reduction of the acoustic energy in each layer of the floor mat for automobiles, that is, the attenuation of noise, the acoustic energy is absorbed by repeated reflection on the inner surface of the sound absorption hole, so that the noise attenuation effect Can be further improved, and quietness can be provided in the automobile interior.

Note that the strength of the adhesive layer (2) decreases when the holes in this case are large or the number of holes is increased. On the other hand, if the number of holes is too small, the ventilation resistance is increased, it becomes difficult for sound to pass, and the sound absorbing effect is lowered.

Furthermore, the sound absorbing holes can be provided in an arbitrary arrangement such as a staggered pattern or a checkered pattern.

In this embodiment, as a method of bonding the upper carpet (1) and the non-slip fiber sheet (6), melting is performed at a temperature that does not adversely affect the fibers constituting the upper carpet (1) and the anti-slip fiber sheet (6). A hot melt sheet made of a polyethylene resin film of 100 to 200 g / m ² is disposed between the upper carpet (1) and the non-slip fiber sheet (6) as the adhesive layer (2), and only the adhesive layer (2). Then, heat treatment was performed at a temperature that can be fused, and bonding was performed by pressure bonding cooling.

By using a polyethylene resin film of 100 to 200 g / m ² as the adhesive layer (2), the upper carpet (1) and the non-slip fiber sheet (6) are bonded together, and then the entire thickness of the automobile floor mat is obtained. The air permeability in the vertical direction can be ensured to 1 to 50 (cm ³ / cm ² · sec). If it is less than 100 g / m ² , the adhesive strength of the bonding cannot be secured, and if it exceeds 200 g / m ² , the air permeability in the thickness direction of the entire automobile floor mat is 1 to 50 (cm ³ / cm ² · sec). Can not be secured.

The adhesive layer (2) to be used is preferably made of a polyolefin-based resin such as polyethylene that does not generate harmful gases when an automobile floor mat is incinerated.

In addition, when the upper carpet (1) and the non-slip fiber sheet (6) are bonded together and then cut into a mat size, the peripheral portion may be unsightly or the fibers may fall off. It is preferable to cover and hide the peripheral edge of the mat that has been bonded by the edge processing (overlock processing) using the yarn, or to cover the peripheral edge by the edge processing (tape lock processing) using a cloth or resin tape.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Example 1) As an upper layer carpet, a polyester yarn having a fineness of 2400 dtex composed of filaments having a single yarn fineness of 40 dtex is formed into a nonwoven fabric (weight: 100 g / m2) made of polyester fibers by a tufting cut pile machine. Tufted carpet with 1/10 gauge (horizontal density: 39 / 10cm), 30 stitches (vertical density: 30 / 10cm), pile length of 8mm, and a cut pile formed (pile weight: 600g / m2) was prepared. Note that a styrene-butadiene rubber latex having a dry mass of 100 g / m ² was applied to the back surface of the carpet to prevent the filament yarn from falling off, thereby forming an upper carpet.

On the other hand, as a non-slip fiber sheet, a nylon short fiber having a single yarn fineness of 1.5 dtex and a length of 0.7 mm is formed by a non-woven fabric made of polyester fiber (weight: 100 g / m ² ) by flocking process (electric flocking process). ) Prepared a fiber sheet in which a dense short fiber group having a weight of short flocked fiber of 100 g / m ² was planted.

Next, a heat-melting sheet made of 30 g / m ^{2 of} polyethylene is disposed between the upper carpet (latex application side) and the non-slip fiber sheet (the surface on which short fibers are not planted), and heat treatment is performed for bonding. Done. Next, from the non-slip fiber sheet side, using a needle-like member, a needle having a diameter of about 2 mm is used, and a small hole is made entirely from the non-slip fiber sheet to the upper carpet at intervals of about 5 mm. Further, the bonded mat was cut into the size of an automobile floor mat, and overlocked with a yarn made of polyester to produce an automobile floor mat having a weight of 1,030 g / m ² .

(Example 2) A floor mat for an automobile was manufactured in exactly the same manner as in Example 1 except that a nylon short fiber having a single yarn fineness of 0.8 dtex was used in the non-slip fiber sheet.

(Example 3) A floor mat for an automobile was manufactured in exactly the same manner as in Example 1 except that a non-slip fiber sheet used a short nylon fiber having a single yarn fineness of 1.8 dtex.

(Example 4) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a short nylon fiber having a length of 0.5 mm was used in the non-slip fiber sheet.

(Example 5) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a short nylon fiber having a length of 1.0 mm was used in the non-slip fiber sheet.

(Example 6) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a nylon short fiber having a short flocked short fiber weight of 85 g / m ² was used in the non-slip fiber sheet.

(Example 7) slip fiber sheet, flocking short flocked short fibers weight in the same manner as in Example 1 except for using nylon short fibers of 115 g / m ^2, was produced automobile floor mats.

Comparative Example 1 Exactly the same as Example 1 except that a 1,700 g / m ² sheet made of synthetic resin was used instead of the non-slip fiber sheet, and an automobile floor mat having a weight of 2,500 g / m ² was produced. Thus, a car floor mat was manufactured.

(Comparative Example 2) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that the non-slip fiber sheet used was a nylon short fiber having a single yarn fineness of 5.0 dtex.

(Comparative Example 3) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a nylon short fiber having a length of 2.0 mm was used in the non-slip fiber sheet.

(Comparative Example 4) A floor mat for an automobile was manufactured in the same manner as in Example 1 except that a nylon short fiber having a flocked short fiber weight of 200 g / m ² was used in the non-slip fiber sheet.

(Comparative Example 5) After laminating the upper carpet and the non-slip fiber sheet, a floor mat for an automobile was manufactured in the same manner as in Example 1 except that no small holes were made on the entire surface.

The anti-slip property of each automobile floor mat obtained as described above was examined based on the following evaluation method. The results are shown in Tables 1 and 2.

(Anti-slip test) Each of the automobile floor mats (100 mm × 140 mm) of Examples 1 to 7 and Comparative Examples 1 to 4 was placed on a general needle punch carpet laid on the automobile floor. The mat was mounted so that the non-slip fiber sheet contacted. Next, with the load of 1 kg applied on the upper carpet of the automobile floor mat, the automobile floor mat is pulled horizontally at a pulling speed of 100 mm / min with respect to the surface of the needle punched nonwoven fabric to slide the automobile floor mat. The frictional resistance force when measured was measured. The results are shown in Table 1. The frictional resistance is an average value of values measured five times. Assuming a case where an automobile floor mat is disposed in an actual automobile room, a frictional resistance of 25 N or more was determined to be an automobile floor mat excellent in slip prevention.

(Sound absorption characteristic test) The sound absorption coefficient was measured according to the normal incident sound absorption coefficient measurement method of ASTM E1050.

(Silence evaluation method) The above sound absorption characteristics were evaluated by evaluating whether the sound absorption characteristics were 0.1 or more at both frequencies of 1000 Hz and 2000 Hz, and the sound absorption coefficient was 0.3 or more. Those with a sound absorption rate of less than 0.1 were evaluated as rejected with a quietness of “x”.

As is clear from Table 1, it was found that the automobile floor mats of the present invention shown in Examples 1 to 7 are lightweight, have high static friction resistance, and are excellent in slip resistance.

On the other hand, Comparative Example 1 was a very heavy automobile floor mat, and Comparative Examples 2 to 4 could not secure anti-slip properties. Further, in Comparative Example 5, an excellent sound absorbing property could not be exhibited.

It is a schematic sectional drawing of the floor mat for motor vehicles concerning one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ......... Upper carpet 2 ......... Adhesive layer 3 ......... Base layer 4 ......... Flocked adhesive layer 5 ......... Short fiber group 6 ......... Slip-proof fiber sheet 7 ......... Sound absorption hole

Claims (5)

An automotive floor mat comprising an upper carpet, an anti-slip fiber sheet, and an adhesive layer, and a fiber structure having a dense flocked short fiber group in which nylon short fibers are planted in a base layer made of a synthetic fiber nonwoven fabric. A floor mat for an automobile comprising: a pile surface of the upper carpet and a surface on which the nylon short fibers of the non-slip fiber sheet are planted, and bonded together with an adhesive layer. The anti-slip fiber sheet is made of polyester fiber and coated with a flocking adhesive on a non-woven fabric having a weight of 80 to 120 g / m ² , and the short fiber made of synthetic fiber is 80 to 120 g / m ^{2 in} a ratio of Flocky. It has a dense flocked short fiber group planted by processing (electric flocking process), and is a very lightweight non-slip fiber sheet having a total weight of 160 to 240 g / m ² . Automotive floor mat. The short fibers planted by the flocking process (electric flocking process) on the non-slip fiber sheet are short fibers made of nylon having a length of 0.4 to 1.0 mm and a thickness of 0.7 to 2.0 dtex. Item 3. A floor mat for automobiles according to Item 1 or 2. After attaching the anti-slip fiber sheet in which the upper layer carpet and the flocked short fiber group are planted together by the adhesive layer, from the anti-slip fiber sheet side, using a needle-like member, from the anti-slip fiber sheet side, A large number of small holes are formed through the upper carpet and the non-slip fiber sheet, and the air permeability in the thickness direction of the entire automobile floor mat is 1 to 50 (cm 3 / cm 2 · sec). The automobile floor mat according to claim 1, wherein the floor mat is used. 5. The automobile floor mat according to claim 1, wherein the adhesive layer for bonding the upper carpet and the anti-slip fiber sheet is a polyethylene resin film of 100 to 200 g / m ² .