JP2607437B2 - Automobile carpet having a backing layer composed of a plurality of layers - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to an automobile carpet laid on an automobile floor panel. In particular, the present invention relates to a laminated structure of a backing layer provided on the back of a floor carpet.

[Conventional technology]

In general, carpets for automobiles are formed according to the shape of the floor and then laid on the floor of the automobile. Conventionally, low-density polyethylene resin is
Backing thermoplastic resin such as vinyl acetate copolymer,
This backing layer was press-formed in a state where it was melted and softened by an infrared heater or the like. In recent years, since sound insulation and flat feeling when laying a carpet on a floor panel have been required, urethane foam is provided on the back surface by injection foaming after press molding. To explain the conventional urethane injection foam molding, prepare a carpet lined with a non-woven fabric as a thermoplastic resin and a secondary base fabric on the back surface, heat the back surface with an infrared heater or the like, soften it, and place it on the lower mold. The carpet is formed into a floor shape by pressing with the upper mold.
After molding, the carpet is set in the injection foaming mold, and a urethane raw material is injected into the cavity of the mold to perform foam molding.

[Problems to be Solved by the Invention] In the carpet formed as described above, the urethane raw material seeps into the carpet surface at the rising portion such as the side portion or the tunnel portion of the floor, that is, the bent portion, and impairs the appearance. Since the rising portion is deeper than the general portion, it is considered that a minute hole in the backing layer oozes out during molding. In order to solve this problem, a method of removing the filler such as calcium carbonate which is conventionally filled in the backing material or increasing the basis weight of the thermoplastic resin of the backing layer can be considered, but the cost increases, Or the thickness of the backing layer becomes thick, resulting in a disadvantage such as poor cushioning property. Therefore, in the past, as a measure to prevent oozing on the carpet surface, a gum tape was attached to the back of the carpet corresponding to the area oozing on the carpet surface, and urethane was injected and foamed, but molding was carried out. It requires man-hours and has low productivity, so improvement in productivity has been desired.

[Means for solving the problem]

Means of the present invention for solving the above problems, the backing layer provided on the back of the carpet, the first backing layer in order from the back of the carpet, a secondary backing layer, a second backing layer, a tertiary backing layer is constituted. A carpet having a backing layer composed of a plurality of layers, characterized in that urethane is injected and foamed on the back surface of the tertiary base fabric layer.

SUMMARY OF THE INVENTION An object of the present invention is to provide a high-quality, good-looking floor carpet that overcomes the above problems, is inexpensive, does not increase the weight of the carpet, and does not cause urethane to seep onto the carpet surface.

[Action]

Since the backing of the carpet is double-backed with a first backing layer, a secondary substrate layer, a second backing layer, and a tertiary backing layer, the urethane raw material is the same as the backing surface of the tertiary backing layer even if the urethane is injected and foamed. The one backing layer or the secondary base fabric layer prevents entry and does not exude to the carpet surface.

〔Example〕

Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a sectional view of one embodiment of the present invention. In this figure, a floor carpet 1 has a first backing layer 3 made of a thermoplastic resin laminated on the back surface of a carpet material 2, and a secondary backing layer 4 laminated on the back surface of the first backing layer 3. As the material of the carpet material 2, a needle punch carpet, tufted carpet, or the like is used. As the backing layer 3, a low-density polyethylene, polypropylene, ethylene-vinyl acetate copolymer, or a Brent product of polyethylene and ethylene-vinyl acetate copolymer There is. As the secondary base fabric layer 4 used in the present invention, a spunbond nonwoven fabric such as polyester, nylon, and polypropylene is used. Further, a second backing layer 5 of the same or different material as the first backing layer 3 is laminated on the back surface of the secondary backing layer 4, and a tertiary base material of the same or different material as the second backing layer 4 is formed on the back surface. Cloth layer 6
Are laminated. Next, an example of the present invention and a comparative example will be described, and both will be compared and evaluated.

FIG. 2 is a schematic explanatory view of one embodiment of the floor carpet manufacturing means of the present invention. In this figure, a tufted carpet material 2 (pile weight 500 g / m ² ) obtained by tufting a nylon yarn wound in a roll shape has a T
A blend resin of polyethylene and ethylene-vinyl acetate copolymer (a basis weight of 300 g / m ² ) is extruded by a die 7 and laminated as a first backing layer 3. Mixing ratio of blend resin of polyethylene and ethylene vinyl acetate copolymer is 80:20
And the vinyl acetate content in the ethylene-vinyl acetate copolymer was in the range of 5 to 30%. If the vinyl acetate content is less than 5%, the rigidity is too high, and the cushioning property is deteriorated. If the vinyl acetate content is more than 40%, the rigidity of the carpet is reduced, and the mounting work is deteriorated. In this backing step, when the backing layer is in a molten state, a polyester spunbonded nonwoven fabric prepared in a roll form in advance (weight per unit area)
15 g / m ² ) as the secondary base fabric layer 4. Then, they are pressed by a pair of pressing rolls 8. Thus, the first backing layer 3 is formed. Next, on the back surface of the secondary base fabric layer 4,
As the second backing layer 5, the same polyethylene and ethylene vinyl acetate copolymer Brent resin (basis weight: 100 g / m ² ) as the first backing layer was extruded and laminated by the T-die 9. And before the second backing layer 5 solidifies, the second backing layer 5
A polyester spunbonded nonwoven fabric (basis weight) as a tertiary base fabric layer 6 prepared in a roll form in advance on the back surface of
35 g / m ² ). Then, they are pressed by a pair of pressing rolls 10. The backing layer-prepared carpet raw material thus produced is heated from the back side with an infrared heater or the like to heat and soften the thermoplastic resin, and then placed on a lower mold and pressed with the upper mold to form a carpet. Form into a floor shape. Immediately after molding, the outer periphery is trimmed to a desired shape. Then, the molded carpet is set in an injection foaming mold, and a urethane raw material is injected into a cavity of the mold to perform foam molding.

As next comparative example, tough Crested carpet material 2 of the same material as the Example '(pile fabric weight 500 g / m ²⁾ polyethylene and ethylene vinyl acetate copolymer blend resin on the back surface of the (basis weight 400 g / m ²⁾ As a backing layer 3 '. The mixing ratio of the polyethylene and ethylene-vinyl acetate copolymer Brent resin was 80:20, and the vinyl acetate content in the ethylene-vinyl acetate copolymer was in the range of 5 to 30%. As the secondary base fabric layer 4 ', a polyester spunbond nonwoven fabric (basis weight: 50 g / m ² ) was used and laminated on the back surface of the backing layer 3'. FIG. 3 shows a cross-sectional view of the comparative example. This carpet was molded into a floor shape in the same manner as in the example, and urethane was injected and foamed over the entire back surface of the molded floor carpet 1 '.

The above Examples and Comparative Examples were evaluated and compared by the following evaluation items.

Evaluation Items 1. Leachability Urethane is injected and foamed on the back of the backed carpet, and the degree of urethane leaching on the carpet surface is evaluated.

Evaluation criteria:…: no exudation, △: exudation to the extent that good quality is obtained by rework.

2. Flexural stiffness Three test specimens each having a flow of 200 mm and a width of 25 mm were taken from the vertical and horizontal directions. Place the test piece backing layer down on a smooth surface with a 45 ° slope at one end, then slide in the direction of the slope at a speed of about 5 mm / sec. Read the distance traveled by the other end when touching the slope.

Evaluation criteria: It is preferable that the moving distance be in the range of 140 mm to 160 mm.

 Table 1 shows the evaluation results.

In Table 1, the bending stiffness of the comparative example is not much different from that of the example of the present invention, and the superiority of the cushioning property is not seen. Regarding the bleeding property, the bleeding property was slightly exuded in the comparative example, but in the example of the present invention, there was no bleeding and the effect of double backing was obtained.

〔The invention's effect〕

Since the backing layer is divided into two layers and backed as in the above evaluation results, the penetration of the urethane raw material to the carpet surface is prevented, and no seepage occurs. For this reason, the step of sticking a gum tape for preventing the exudation of urethane on the back side of the carpet becomes unnecessary, and the step is shortened, and productivity is remarkably improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of one embodiment of the present invention, FIG. 2 is a schematic explanatory view of one embodiment of a production means of the present invention, and FIG. 3 is a cross-sectional view of a backing layer of a comparative example. 1, 1 '... floor carpet, 2, 2' ... carpet material, 3, 3 '... first backing layer, 4, 4' ... secondary backing layer, 5 ... second backing layer, 6 ... Tertiary base fabric layer, 7 T die, 8 pair of press rolls, 9 T die, 10 pair of press rolls.

Claims (1)

(57) [Claims] 1. A backing layer provided on the back of a carpet,
It consists of a first backing layer, a secondary backing layer, a second backing layer, and a tertiary backing layer in order from the back side of the carpet, and is composed of a plurality of layers characterized in that urethane is injected and foamed on the back side of the tertiary backing layer. Automotive carpet with backing layer