JP2008184078A - Vehicular sound absorbing and sound insulating carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a vehicular sound absorbing and sound insulating carpet capable of securing silence in a vehicle by exhibiting superior sound absorptivity even to noise intruded from a roof, a door and a window of the vehicle, and also to have an effect on noise and vibration entering from the lower side of a floor of the vehicle. <P>SOLUTION: A carpet skin material and a sound absorbing layer are integrated via a ventilating adhesive resin layer, and after setting a ventilation degree in the thickness direction in its state to a specific range, nonventilative sound insulating layer composed of a thermoplastic resin is further layered on the lowest layer, and a vehicular carpet of imparting superior sound insulating performance in addition to the sound absorptivity can be provided to achieve this heading invention. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a carpet for a vehicle that prevents vibration and noise entering from the outside of the vehicle, absorbs noise inside the vehicle, ensures sufficient silence, and creates a comfortable vehicle interior. In this specification, “air permeability” is the air permeability measured by the A method of 827.1 of JISL 1096-1999.

  Conventionally, floor carpets and mats have been laid on the floors of vehicles such as automobiles to prevent the human body from directly touching the metal plates on the car body floor, improving the feeling of stepping, as well as vibration from the floor and from outside the vehicle. It has been used for the purpose of blocking noise and creating a comfortable interior space.

  However, in order to prevent these vibrations and noises, the technology that has been used in the past is to seal the vibrations and noises by laminating an airtight heavy layer made of thermoplastic resin as the sound insulation layer under the skin material. I have taken measures to do. However, these sound insulation layers have to increase the weight in order to increase the sound insulation effect, which is not a preferable measure from the viewpoint of energy saving. Patent Document 1 proposes a carpet for a vehicle that can obtain sound absorption performance in addition to sound insulation performance, in which a sound absorption layer composed of a felt layer is integrated via a TPE layer below the carpet skin layer. The carpet skin layer and the felt layer mainly play a sound absorbing action, and the TPE layer plays a sound insulating layer. In addition, in the patent document 2, the applicant of the present invention is a vehicle in which a sound absorbing layer made of a nonwoven fabric is integrated with a carpet skin material through a breathable adhesive layer using a thermoplastic resin powder, particularly for a vehicle having an excellent sound absorbing effect. Proposed as a carpet.

JP-A-2005-47468 JP-A-2002-219989

  By the way, there are many sources of external noise entering the vehicle, such as vibration and noise from vehicle engines, those generated from gearboxes and auxiliary units, those generated from exhaust systems, and those generated from wind and tires. Only when all these noises and vibrations are effective, the interior of the vehicle is kept quiet. However, in the prior art, a heavy and non-breathable sound insulation layer is effective for noise and vibration (relatively low frequency sound) entering from the underside of the vehicle floor. Development of a carpet for vehicles that can achieve both sound insulation performance and sound absorption performance because it is considered that an air-absorbing sound-absorbing layer is effective against noise that enters through the sound (relatively high frequency sound). Has been considered difficult as a conflicting theme.

  The present invention has been made in view of such a technical background, and blocks noise and vibration entering from the underside of the vehicle floor, and is excellent in sound absorption even for noise entering from the roof, door, window, etc. of the vehicle. The present invention is to provide a carpet for a vehicle that can exhibit the performance and ensure the quietness in the vehicle.

  As a result of intensive studies to solve such problems, the inventors of the present invention have integrated the carpet skin material and the sound absorbing layer via the breathable adhesive resin layer, and the thickness of the carpet in that state. After setting the air permeability in a certain direction to a specific range, a relatively light-weight, non-breathable, sound-insulating layer made of a thermoplastic resin is laminated on the bottom layer to achieve sound insulation without significantly reducing sound absorption performance. The present inventors have found that a vehicular carpet that is effective and lighter than a conventional sound insulating carpet can be obtained. The present invention provides the following means.

[1] A vehicle characterized in that a sound insulation layer made of a thermoplastic resin is laminated on a carpet for a vehicle in which a skin material layer and a sound absorbing layer made of a nonwoven fabric are integrated via a breathable adhesive resin layer. Carpet.

[2] The sound absorbing layer made of the nonwoven fabric has a thickness of 1 to 15 mm, an apparent density of 0.01 to 0.5 g / cm ³ , and the fineness of the fibers constituting the sound absorbing layer is in the range of 0.1 to 30 dtex. The vehicle carpet according to item 1 above, wherein the air permeability is 1 to 60 (cm ³ / cm ² · sec) when the sound absorbing layer and the skin material layer are integrated with each other through a breathable adhesive resin layer.

[3] The vehicle carpet according to the above item 1 or 2, wherein the thermoplastic resin of the breathable adhesive resin layer is a polyolefin resin powder.

[4] The thermoplastic resin of the breathable adhesive resin layer is a polyethylene resin powder having a melt flow rate of 1 to 200, a coating amount of 150 to 500 g / m ² , and a particle size of 320 to 1000 μm. The vehicle carpet according to any one of the preceding items 1 to 3, wherein

[5] The vehicle carpet according to any one of items 1 to 4, wherein the sound insulating layer made of the thermoplastic resin is a polyolefin resin.

[6] The vehicle according to any one of items 1 to 5, wherein the sound insulating layer made of the thermoplastic resin is a polyethylene resin having a melt flow rate of 1 to 100 and an application amount of 150 to 500 g / m ² . carpet.

  In the invention of [1], the sound insulating layer made of a thermoplastic resin is laminated on the carpet for the vehicle in which the skin material layer and the sound absorbing layer made of a nonwoven fabric are integrated via a breathable adhesive resin layer. It can be set as the carpet for vehicles which has a sound absorption performance and a sound insulation effect.

In the invention of [2], the thickness of the sound absorbing layer is 1 to 15 mm, the apparent density of the sound absorbing layer is 0.01 to 0.5 g / cm ³ , and the fineness of the fibers constituting the sound absorbing layer is 0.1 to 30 dtex. And the air permeability when the sound absorbing layer and the skin material layer are integrated with each other through the breathable adhesive resin layer is 1 to 60 (cm ³ / cm ² · sec). Sound absorption performance is exhibited in high frequency areas such as, and a sound insulation layer made of thermoplastic resin exhibits low frequency sound insulation performance such as tires and engine sounds, and can be used as a carpet for a vehicle that keeps the interior of a vehicle quiet. .

  In the invention of [3], since the thermoplastic resin of the breathable adhesive resin layer is a polyolefin resin powder, it has breathability and can further improve the adhesive strength, and can be recycled if the carpet material is unified with the polyolefin resin. Even if a fire occurs due to an accident, it can be a safe vehicle carpet that does not generate harmful gases.

In the invention of [4], the thermoplastic resin of the breathable adhesive resin layer is a polyethylene resin powder having a melt flow rate of 1 to 200, an application amount of 150 to 500 g / m ² , and a particle size of 320 to 1000 μm. Therefore, the skin material layer and the sound absorbing layer made of a nonwoven fabric can be firmly integrated in a state where air permeability is ensured.

  In the invention of [5], since the sound insulating layer made of the thermoplastic resin is a polyolefin resin, the sound absorbing layer made of a non-woven fabric is firmly bonded to form a sound insulating layer having no air permeability from the underside of the carpet from the vehicle interior. The sound of entering the vehicle can be reflected and sound-insulated, and the vehicle carpet can be excellent in recyclability and safety.

In the invention of [6], since the sound insulating layer made of the thermoplastic resin is a polyethylene resin having a melt flow rate of 1 to 100 and an application amount of 150 to 500 g / m ^2, it is made of a nonwoven fabric by a T-die extruder. The polyethylene resin can be melt-extruded in the form of a film under the sound-absorbing layer, and the polyethylene resin stays on the surface of the sound-absorbing layer made of a non-woven fabric to form a sound-insulating layer having no air permeability. Reflecting sound insulation performance is imparted, and the vehicle carpet can be made lightweight and recyclable.

  As shown in FIG. 1, a vehicle carpet 1 according to the present invention has a skin material layer 2 and a nonwoven fabric sound-absorbing layer 3 bonded and integrated through a breathable adhesive resin layer 4 made of a thermoplastic resin. A sound-insulating layer 5 made of a thermoplastic resin and having no air permeability is laminated below the sound-absorbing layer 3.

  The skin material layer 2 may have a pile on the surface thereof, or may have either no pile, and is not particularly limited. Examples of the former include tufted carpets, woven carpets, knitted carpets, and electrodeposited carpets, and examples of the latter include needle punched nonwoven fabrics. The material of the skin material layer 2 is not particularly limited, and is composed of synthetic fibers such as polyester fibers, polyamide fibers, polypropylene fibers, and acrylic fibers, or fibers such as natural fibers such as hemp, cotton, and wool. However, from the viewpoints of recyclability and safety, it is preferably made of an olefin fiber.

  Any material can be used for the nonwoven fabric sound absorbing layer 3 without any particular limitation. For example, a needle punched nonwoven fabric, a water needle nonwoven fabric, a spunbonded nonwoven fabric, or a wool felt is used. The fibers constituting the nonwoven fabric sound absorbing layer are not particularly limited and are composed of synthetic fibers such as polyester fibers, polyamide fibers, polypropylene fibers and acrylic fibers, or fibers such as natural fibers, from the viewpoint of recyclability and safety. Is preferably made of olefin fiber.

  The thickness of the nonwoven fabric sound absorbing layer 3 is preferably 1 to 15 mm. If it is less than 1 mm, a sufficient sound absorbing effect cannot be obtained, and if it exceeds 15 mm, the height of the interior space of the vehicle is reduced, and there is no room for the space in the vehicle, which is not preferable in terms of cost.

The apparent density of the nonwoven fabric sound absorbing layer 3 is preferably 0.01 to 0.5 g / cm ³ . If it is less than 0.01 g / cm ³ , a sufficient sound absorbing effect cannot be obtained, and if it exceeds 0.5 g / cm ³ , it is not preferable because it is impossible to secure a light weight as a vehicle carpet.

  It is preferable to use a fiber having a fineness of 0.1 to 30 dtex in the nonwoven fabric sound-absorbing layer 3, and if it is less than 0.1 dtex, low frequency noise is hardly absorbed and cushioning properties are also reduced. Is also not preferable. If it exceeds 30 dtex, it is difficult to absorb high-frequency noise, which is not preferable. Among these, the fineness of the fibers constituting the nonwoven fabric sound absorbing layer 3 is more preferably in the range of 0.1 to 15 dtex.

The breathable adhesive resin layer 4 is preferably a resin having a melt flow rate of 1 to 200 and a coating amount of 150 to 500 g / m ² . When the melt flow rate is less than 1, it is difficult to apply uniformly, and it is difficult to secure a target air permeability of 1 to 60 (cm ³ / cm ² · sec) in the thickness direction, which is not preferable. When the melt flow rate exceeds 200, the resin penetrates too much into the skin material layer 2 and the nonwoven fabric sound absorbing layer 3, and it is not preferable because sufficient adhesive strength cannot be obtained. On the other hand, if the coating amount is less than 150 g / m ² , the adhesive strength cannot be obtained, which is not preferable. When the coating amount exceeds 500 g / m ² , the air permeability is insufficient, it is difficult to ensure the target air permeability of 1 to 60 (cm ³ / cm ² · sec), and this is not preferable in terms of cost and workability.

In the present invention, the air permeability in the thickness direction of the carpet before the sound insulation layer 5 is laminated needs to be set in the range of 1 to 60 (cm ³ / cm ² · sec). For reasons like this. That is, if the air permeability is less than 1 (cm ³ / cm ² · sec), the noise that has entered from the top through the roof, windows, doors, etc. is sufficient to return to the vehicle interior space without being absorbed. Silence cannot be ensured, and when the air permeability exceeds 60 (cm ³ / cm ² · sec), the sound absorbing layer cannot reflect the sound reliably and is reflected by the sound insulating layer 5 again. This is because noise that leaks into the interior space of the vehicle is generated, and sufficient silence cannot be ensured.

  As the sound insulation layer 5, it is better to laminate a heavy airtight weight layer made of thermoplastic resin under the sound absorbing layer 3 so as to reflect and insulate the sound entering the vehicle compartment from the underside of the carpet. There is, however, a requirement for weight reduction cannot be satisfied. Therefore, in the present invention, a light and non-breathable polyolefin-based resin made of a thermoplastic resin is laminated to reflect the sound of entering the passenger compartment from the underside of the carpet, thereby obtaining a sound insulation effect.

The sound insulation layer 5 made of the thermoplastic resin is preferably a polyethylene resin having a melt flow rate of 1 to 100 and an application amount of 150 to 500 g / m ² . If the melt flow rate is less than 1, it is difficult to apply uniformly, and if it exceeds 100, the resin penetrates too much into the nonwoven fabric sound absorption layer 3 and a sufficient sound insulation layer cannot be formed. Moreover, in the situation where the coating amount is less than 150 g / m ² , it is impossible to form a firm sound insulating layer. Further, when the coating amount exceeds 500 g / m ² , the object of reducing the weight of the entire vehicle carpet cannot be achieved.

  The resin type of the sound insulation layer 5 is not particularly limited as long as it is a polyolefin-based thermoplastic resin, but a polyethylene resin is preferable from the viewpoint of strength and recyclability. Among these polyolefin resins, polyethylene is superior in cost. Because it is a polyolefin-based resin, it adheres firmly to the sound absorbing layer made of non-woven fabric, becomes a sound-insulating layer that is not breathable, and can reflect and insulate sound from entering the passenger compartment from the underside of the carpet, making it recyclable It can be set as the vehicle carpet excellent in.

  The vehicle carpet 1 of the present invention can be manufactured as follows, for example. As shown in FIG. 2, the thermoplastic resin powder 6 is spread on the skin material layer 2 and heated and melted in a heating furnace 7, and the non-woven sound absorbing layer 3 is overlaid thereon. A thermoplastic resin 9 melt-extruded in the form of a film by a machine 8 is applied and pressed and sandwiched by a nip roll 10 to form a sound insulation layer 5.

  The nip roll 10 is preferably a cooling roll. When pressure is applied with a cooling and pressing roll, forced cooling can be performed simultaneously with lamination, so that the molten thermoplastic resin 9 can be solidified earlier and productivity can be improved.

  Further, the skin material layer 2 and the nonwoven fabric sound absorbing layer 3 can be used together with antistatic processing, insect repellent processing, flame retardant processing, antifouling processing, deodorization processing, and the like.

  Next, specific examples of the vehicle carpet of the present invention will be described. In addition, the carpet for vehicles and the manufacturing method of this invention are not limited to an Example.

<Example 1>
As shown in FIG. 1 and FIG. 2, pile yarn 2-1 made of nylon fiber is tufted (pile basis weight 450 g / m ² ) on a polyester fiber base fabric 2-2 having a basis weight of 100 g / m ^2. In order to fix the base fabric, it is transported at a constant speed with the pile side of the skin material layer 2 on which the sealing layer 2-3 made of SBR latex is applied downward, the melt flow rate is 38, the particle size Is coated with 250 g / m ² of polyethylene resin powder having a thickness of 330 μm, heated in a heating furnace 7 at 400 ° C. for 10 seconds, and melted to obtain a nonwoven fabric sound absorbing layer 3 (polyester fiber (6.6 dtex / 4.4 dtex = 70 weight). % / 30% by weight) and a needle punched nonwoven fabric having an apparent density of 0.1 g / cm ^3. A polyethylene resin having a melt flow rate of 38 was melt-extruded in a film form at a coating amount of 200 g / m ² , and immediately thereafter pressure-cooled by the nip roll 10 to form the sound insulating layer 5, thereby obtaining a vehicle carpet 1. In this carpet, the air permeability in the thickness direction at the stage before the sound insulating layer 5 was laminated was 25 (cm ³ / cm ² · sec). Next, the transmission loss and the normal incidence sound absorption coefficient in each frequency range were measured and displayed in FIGS.

<Comparative Example 1>
A vehicle carpet 1 was obtained in the same manner as in Example 1 except that a vehicle carpet without the sound insulation layer 5 laminated in Example 1 was obtained. FIGS. 3 and 4 show the transmission loss and the normal incident sound absorption coefficient in each frequency range, which are displayed together with Example 1. The normal incident sound absorption coefficient is not so different from that of Example 1, but the sound insulation performance (transmission loss) is shown. ) There was a difference of about 10 dB. That is, Example 1 was able to improve the sound insulation effect without significantly reducing the sound absorption effect as compared with Comparative Example 1.

<Sound absorption characteristic evaluation method>
The sound absorption coefficient was measured based on the normal incident sound absorption coefficient measurement method of ASTM E1050.

<Sound insulation characteristic evaluation method>
Transmission loss was measured in accordance with JIS A 1416.

It is a schematic sectional drawing of the carpet for vehicles concerning one Embodiment of this invention. It is a figure which shows the manufacturing method of this invention roughly. It is a graph which shows the normal incidence sound absorption coefficient of Example 1 and Comparative Example 1 of this invention. It is a graph which shows the transmission loss of Example 1 and Comparative Example 1 of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Car carpet 2 ... Skin material layer 2-1 ... Pile 2-2 ... Base fabric 2-3 ... Sealing layer 3 ... Nonwoven fabric sound absorption layer 4 ... Adhesion Resin layer 5 ... Sound insulation layer 6 ... Thermoplastic resin powder 7 ... Heating furnace 8 ... T-die extruder 9 ... Melt extruded thermoplastic resin 10 ... Nip roller

  The present invention relates to a carpet that prevents vibration and noise entering from the outside of a vehicle such as an automobile or a railway, absorbs noise inside the vehicle, ensures sufficient silence, and creates a comfortable vehicle interior. Besides, it is also widely used as indoor carpets that require quietness.

Claims (6)

  A vehicle carpet, wherein a sound insulation layer made of a thermoplastic resin is laminated on a vehicle carpet in which a skin material layer and a sound absorbing layer made of a nonwoven fabric are integrated via a breathable adhesive resin layer. The sound absorbing layer made of the nonwoven fabric has a thickness of 1 to 15 mm, an apparent density of 0.01 to 0.5 g / cm ³ , and the fineness of the fibers constituting the sound absorbing layer is in the range of 0.1 to 30 dtex, The vehicle carpet according to claim 1, wherein the air permeability when the layer and the skin material layer are integrated through a breathable adhesive resin layer is 1 to 60 (cm ³ / cm ² · sec).   The carpet for vehicles according to claim 1 or 2 whose thermoplastic resin of said breathability adhesion resin layer is polyolefin resin powder. The thermoplastic resin of the breathable adhesive resin layer is a polyethylene resin powder having a melt flow rate of 1 to 200, an application amount of 150 to 500 g / m ² , and a particle size of 320 to 1000 μm. The carpet for vehicles as described in any one of Claims 1 thru | or 3.   The vehicle carpet according to any one of claims 1 to 4, wherein the sound insulating layer made of the thermoplastic resin is a polyolefin resin. The heat sound insulation layer made of a thermoplastic resin in melt flow rate is 1 to 100, vehicular carpet according to claim 1 is a polyethylene resin is coated amount 150~500g / ^{m 2.}

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