JP4712840B2 - Car-mounted carpet and method for manufacturing the same - Google Patents
Car-mounted carpet and method for manufacturing the same Download PDFInfo
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- JP4712840B2 JP4712840B2 JP2008183835A JP2008183835A JP4712840B2 JP 4712840 B2 JP4712840 B2 JP 4712840B2 JP 2008183835 A JP2008183835 A JP 2008183835A JP 2008183835 A JP2008183835 A JP 2008183835A JP 4712840 B2 JP4712840 B2 JP 4712840B2
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
- D05C17/02—Tufted products
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23979—Particular backing structure or composition
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Passenger Equipment (AREA)
- Carpets (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、自動車の車室内の床面上に載置される車載用カーペット及びその製造方法に係り、特にニードルパンチ不織布からなる裏面側部材とを備えた車載用カーペット及びその製造方法に関する。 The present invention relates to an on-vehicle carpet placed on a floor surface in a vehicle cabin and a method for manufacturing the same , and more particularly to an on-vehicle carpet provided with a back-side member made of a needle punched nonwoven fabric and a method for manufacturing the same .
一般的に、自動車車室内の床面は、フロアパネル上に、所定の吸音部材が配置され、更に上記吸音部材の上面側にはいわゆるラインマットと称される下地用カーペット部材が敷設されている。
上記下地用カーペット部材の上面側には、車室内の外観品質の向上を目的として、いわゆるオプションマットと称される車載用カーペットが敷設されており、一般的に上記車載用カーペットは、基布上にパイルがタフトされた、いわゆるタフテッドカーペットのカーペット地の裏面に、所定の裏面側部材が接合されて形成されている。
Generally, a predetermined sound absorbing member is disposed on a floor panel on a floor surface in an automobile interior, and a base carpet member called a line mat is laid on the upper surface side of the sound absorbing member. .
On the upper surface side of the base carpet member, for the purpose of improving the external appearance quality of the vehicle interior, an in-vehicle carpet called a so-called option mat is laid. A predetermined back surface side member is joined to the back surface of the carpet surface of a so-called tufted carpet to which the pile is tufted.
自動車の走行中、上記車載用カーペットは、運転者の足等によって頻繁に摩擦を受ける。
この際、上記車載用カーペットが上記下地用カーペット部材上で滑動すると、車室内の外観品質が低下することはもとより、上記車載用カーペットがアクセル／ブレーキペダル等に挟まり、アクセル／ブレーキペダル等の動作を阻害する恐れがあり、安全上の観点からも大きな問題となる。
従って、車室内での滑動を防止するために、車載用カーペットの裏面側部材に防滑用の突起部を設けた車載用カーペットが提案されている（特許文献１）。
図６に示すように、上記特許文献１にかかる車載用カーペット７０は、表材７１の下面側に熱可塑性エラストマーからなる弾性層７２が積層一体化されると共に、上記弾性層７２の下面７３に多数の防滑用突起７４が相互に間隔をあけて縦横に整列状態に配置されて形成されている。
また、上記防滑用突起７４は、円盤状にされた台座部７５の下方に、垂下状のスパイク状突起７６が突設されて形成されている。
上記車載用カーペット７０を車室内に敷設した場合は、上記防滑用突起７６が上記下地用カーペット部材（図６には図示せず）のパイル内部に侵入して係合し、上記車載用カーペットが上記下地用カーペット部材上で滑動することを防止する。
しかしながら、上記車載用カーペット７０の弾性層７２は熱可塑性エラストマーからなるため、吸音作用を有しておらず、弾性層７２により走行音や社内騒音が反射され、車体に施されている吸音部材の効果を阻害してしまうという不具合を有していた。
While the vehicle is running, the on-vehicle carpet is frequently subjected to friction by the driver's feet and the like.
At this time, when the on-vehicle carpet slides on the underlying carpet member, the appearance quality in the passenger compartment is deteriorated, and the on-vehicle carpet is sandwiched between the accelerator / brake pedal and the operation of the accelerator / brake pedal and the like. This is a big problem from the viewpoint of safety.
Therefore, in order to prevent sliding in the vehicle interior, a vehicle-mounted carpet in which an anti-slip protrusion is provided on the back side member of the vehicle-mounted carpet has been proposed (Patent Document 1).
As shown in FIG. 6, in the on-vehicle carpet 70 according to Patent Document 1, an elastic layer 72 made of a thermoplastic elastomer is laminated and integrated on the lower surface side of a surface material 71, and on the lower surface 73 of the elastic layer 72. A large number of anti-slip projections 74 are formed in an aligned manner in the vertical and horizontal directions at intervals.
The anti-slip protrusion 74 is formed by projecting a hanging spike-like protrusion 76 below the disk-shaped pedestal 75.
When the on-vehicle carpet 70 is laid in the vehicle interior, the anti-slip projection 76 enters and engages inside the pile of the base carpet member (not shown in FIG. 6), and the on-vehicle carpet is The sliding on the carpet member for the ground is prevented.
However, since the elastic layer 72 of the on-vehicle carpet 70 is made of a thermoplastic elastomer, the elastic layer 72 does not have a sound absorbing action. The elastic layer 72 reflects running noise and in-house noise, and the sound absorbing member applied to the vehicle body. It had a problem of inhibiting the effect.
上記不具合を受け、防滑効果と走行音等の吸音効果を共に有する車載用カーペットが提案されている（特許文献２）。
図７に示すように、上記特許文献２に係る車載用カーペット８０は、表面材８１と、上記表面材８１の一方面に貼設された裏面材８２から形成されている。
上記裏面材８２は、ニードルパンチ加工により裏面に繊維８３を突出させ、上記突出させた繊維８３をシャーリングし、更に熱処理によって上記繊維８３の経寸法よりも大きな樹脂塊８４を形成することで製造されている。
上記車載用カーペット８０を車室内の下地カーペット部材（図７には図示せず）に敷設した場合は、上記樹脂塊８４が、上記下地用カーペット部材のパイル内部に侵入して係合することで、上記車載用カーペット８０が上記下地用カーペット部材上で滑動することを防止するとともに、上記裏面材８２がニードルパンチ加工によって製造された不織布であることから、走行音や社内騒音を反射することなく吸収することから、車体に施されている吸音部材の効果を阻害してしまうことがない。
In response to the above problems, an on-vehicle carpet having both an anti-slip effect and a sound absorption effect such as running sound has been proposed (Patent Document 2).
As shown in FIG. 7, the on-vehicle carpet 80 according to Patent Document 2 is formed of a surface material 81 and a back material 82 pasted on one surface of the surface material 81.
The back surface material 82 is manufactured by protruding fibers 83 on the back surface by needle punching, shearing the protruded fibers 83, and further forming a resin mass 84 larger than the warp dimension of the fibers 83 by heat treatment. ing.
When the on-vehicle carpet 80 is laid on a base carpet member (not shown in FIG. 7) in the vehicle interior, the resin mass 84 enters and engages inside the pile of the base carpet member. The on-vehicle carpet 80 is prevented from sliding on the base carpet member, and the back material 82 is a non-woven fabric manufactured by needle punching, so that it does not reflect running noise or in-house noise. Since it absorbs, the effect of the sound-absorbing member applied to the vehicle body is not hindered.
しかしながら、上記車載用カーペット８０においては、上記下地用カーペット部材が、ニードルパンチカーペットで形成されている場合は、下地用カーペット部材の表面がリング状の繊維で形成されていることから、上記樹脂塊８４が係合し易く防滑効果も大きいが、上記下地用カーペット部材がいわゆるタフテッドカーペットで形成されている場合は、上記下地用カーペット部材の表面が線状の繊維で形成されているため、上記樹脂塊８４が上記下地用カーペット部材の内部に侵入しても、上記下地用カーペット部材の繊維と係合せず、防滑効果が働かないという不具合を有していた。 However, in the on-vehicle carpet 80, when the base carpet member is formed of a needle punch carpet, the surface of the base carpet member is formed of ring-shaped fibers. 84 is easy to engage and has a large anti-slip effect, but when the base carpet member is formed of a so-called tufted carpet, the surface of the base carpet member is formed of linear fibers. Even if the resin mass 84 enters the interior of the base carpet member, it does not engage with the fibers of the base carpet member, and the anti-slip effect does not work.
近年においては、高級乗用車を中心に、より外観品質の高いタフテッドカーペットを下地用カーペット部材に用いるケースが増加している。
上記事情にも関わらず、タフテッドカーペットにおいても優れた防滑効果を有する車載用カーペットは現在に至るまで供給されておらず、自動車業界からの開発要請も非常に大きなものとなっていた。
In recent years, cases of using tufted carpet having higher appearance quality as a base carpet member are increasing, mainly in luxury passenger cars.
In spite of the above circumstances, in-car carpets having an excellent anti-slip effect have not been supplied to date even for tufted carpets, and development demands from the automobile industry have become very large.
上記背景を受け、本発明の技術的課題は、車室内の下地用カーペット部材がタフテッドカーペットである場合にも、優れた防滑効果を有する車載用カーペット、及び上記車載用カーペットの製造方法を提供することにある。 In view of the above background, the technical problem of the present invention is to provide an in-vehicle carpet having an excellent anti-slip effect even when the underlying carpet member in the vehicle interior is a tufted carpet, and a method for manufacturing the in-vehicle carpet. There is to do.
上記課題を解決するため、請求項1に記載した発明にあっては、自動車のフロアパネル上に敷設された下地用カーペット部材上に載置され、カーペット地側基布と、上記カーペット地側基布の表面側から植設されたパイルとからなるカーペット地と、上記カーペット地の裏面側に接合された不織布からなる裏面側部材とを備えた車載用カーペットであって、上記裏面側部材の上記下地用カーペット部材との当接面には、上記下地用カーペット部材上に載置下場合に、車体の幅方向に沿って配置されうる多数の細畝が形成されていることを特徴とする。 In order to solve the above-mentioned problems, in the invention described in claim 1, the carpet base fabric is placed on a base carpet member laid on a floor panel of an automobile, and the carpet base base An on-vehicle carpet comprising a carpet made of a pile planted from the front side of a cloth, and a back side member made of a nonwoven fabric bonded to the back side of the carpet, the carpet of the back side member The contact surface with the base carpet member is formed with a large number of fine ribs that can be arranged along the width direction of the vehicle body when placed on the base carpet member.
従って、上記車体の幅方向に沿って配置されうる複数の細畝が、上記下地用カーペット部材のパイル内部に侵入し、パイル繊維と係合することによって、上記車載用カーペットは上記下地用カーペット部材上に固定され、車体の前後方向に対する滑動を防止する。 Therefore, a plurality of fine lines that can be arranged along the width direction of the vehicle body enter the pile of the base carpet member and engage with the pile fiber, so that the on-vehicle carpet is the base carpet member. It is fixed on the top to prevent the vehicle body from sliding in the longitudinal direction.
また、請求項２に記載した発明にあっては、上記裏面側部材は、上記カーペット地側基布に接合された基布と、上記基布の裏面側に接合され、上記下地用カーペット部材に当接する不織布からなるニードルパンチ加工部とからなり、上記細畝は、複数のニードルパンチ用針を上記不織布に刺突することにより形成され、上記複数のニードルパンチ用針は、不織布の搬送方向に沿って配置された針列が搬送方向に直交する方向に複数設けられ、相互に隣接する針列は、搬送方向に沿った一対の針の間隔寸法の半分の間隔寸法分、搬送方向において互いにずれて設けられていることを特徴とする。 In the invention described in claim 2, the back side member is joined to the carpet base fabric and the back side of the base fabric, to the base carpet member. The fine punch is formed by inserting a plurality of needle punch needles into the non-woven fabric, and the plurality of needle punch needles are arranged in the direction of conveyance of the non-woven fabric. A plurality of needle rows arranged in the direction perpendicular to the transport direction are provided, and the adjacent needle rows are shifted from each other in the transport direction by a distance of half the distance between the pair of needles along the transport direction. It is characterized by being provided.
従ってニードルパンチ加工部の一方面には、上記ニードルパンチ用針の刺突によって、不織布の搬送方向に対して直交する方向の細畝が形成される。
上記細畝は上記ニードルパンチ加工部を形成する不織布内部からニードルパンチ針の刺突によって掻き出された多数の繊維が密集して形成されている。
従って、上記ニードルパンチ加工部を有する車載用カーペットを、上記畝部を下方に向けて、タフテッドカーペットからなる下地用カーペット部材上に載置した場合、上記下地用カーペット部材のパイル内部に、上記細畝を形成する繊維が侵入し、上記下地用カーペット部材のパイルの線状の繊維と、上記細畝の繊維が互いに絡み合うことに加えて、上記細畝そのものが車体前後方向における滑り止めとなり、滑動を防止することから、上記車載用カーペットの、上記下地用カーペット部材上での車体の前後方向に対する滑動は防止される。
Therefore, on one surface of the needle punched portion, fine wrinkles in a direction perpendicular to the nonwoven fabric conveyance direction are formed by the needle punch needle piercing.
The fine wrinkles are formed by densely gathering a large number of fibers scraped from the inside of the nonwoven fabric forming the needle punched portion by the needle punch needle piercing.
Therefore, when the on-vehicle carpet having the needle punched portion is placed on a base carpet member made of a tufted carpet with the collar portion facing downward, the carpet inside the pile of the base carpet member The fibers forming the fine wrinkles infiltrate, in addition to the linear fibers of the pile of the underlying carpet member and the fine wrinkle fibers being intertwined with each other, the fine wrinkles themselves become anti-slip in the longitudinal direction of the vehicle body, Since sliding is prevented, the vehicle-mounted carpet is prevented from sliding in the longitudinal direction of the vehicle body on the base carpet member.
また、請求項３に記載下発明にあっては、上記細畝は、上記裏面側部材の上記下地用カーペット部材との当接面から突出して形成された密集したリング状の繊維の先端部の軌道から形成されていることを特徴とする。
従って、上記ニードルパンチ加工部を裏面側部材に有する車載用カーペットを、上記畝部を下方に向けて、タフテッドカーペットからなる下地用カーペット部材上に載置した場合、上記下地用カーペット部材のパイル内部に、上記細畝を形成するリング状繊維が侵入し、上記下地用カーペット部材のパイルの線状繊維の先端部が上記リング状繊維のリングと係合し、いわゆる面ファスナーの原理によって、上記車載用カーペットは上記下地用カーペット部材上に固定され、車体の前後方向に対する滑動を防止する。
According to a third aspect of the present invention, the fine ridges are formed at the tips of dense ring-shaped fibers formed so as to protrude from the contact surface of the back side member with the base carpet member. It is formed from orbits .
Accordingly, when the on-vehicle carpet having the needle punched portion on the back side member is placed on the base carpet member made of tufted carpet with the collar portion facing downward, the pile of the base carpet member The ring-shaped fibers forming the fine wrinkles enter inside, and the tip ends of the linear fibers of the pile of the base carpet member are engaged with the rings of the ring-shaped fibers. The on-vehicle carpet is fixed on the base carpet member and prevents the vehicle body from sliding in the front-rear direction.
また、請求項４に記載した発明にあっては、上記細畝は上記不織布の搬送方向に沿った針列における直近の２つのニードルパンチ用針の間隔寸法の半分の間隔寸法をおいて形成されていることを特徴とする。
また、請求項５に記載した発明にあっては、上記細畝の間隔寸法は５mmであることを特徴とする。
従って、５ｍｍ間隔毎に多数の細畝が車体幅方向に沿って形成され、車体前後方向における滑動を防止する。
In the invention described in claim 4, the fine wrinkles are formed with an interval dimension that is a half of the interval dimension between the nearest two needle punch needles in the needle row along the conveying direction of the nonwoven fabric. It is characterized by.
The invention described in claim 5 is characterized in that the distance between the narrow ribs is 5 mm.
Accordingly, a large number of fine rods are formed along the width direction of the vehicle body every 5 mm to prevent sliding in the longitudinal direction of the vehicle body.
また、請求項６に記載した発明にあっては、上記不織布はフェルト材であることを特
徴とする。
The invention described in claim 6 is characterized in that the non-woven fabric is a felt material.
また、請求項７に記載した発明にあっては、上記裏面側部材の上記下地用カーペット部材との当接面には、熱可塑性樹脂が含浸されていることを特徴とする。
また、請求項８に記載した発明にあっては、上記熱可塑性樹脂は、アクリル系樹脂であることを特徴とする。
従って、上記熱可塑性樹脂が有している粘性によって、上記車載用カーペットは、上記下地用カーペット部材上に密着した状態で載置される。
The invention described in claim 7 is characterized in that a thermoplastic resin is impregnated on a contact surface of the back surface side member with the base carpet member.
The invention described in claim 8 is characterized in that the thermoplastic resin is an acrylic resin.
Accordingly, the on-vehicle carpet is placed in close contact with the underlying carpet member due to the viscosity of the thermoplastic resin.
また、請求項９に記載した発明にあっては、上記熱可塑性樹脂はスプレーにより、上記裏面側部材に噴霧されていることを特徴とする。
従って、上記熱可塑性樹脂が、上記裏面側部材の上記下地用カーペット部材との当接面において均一に含浸する。
The invention described in claim 9 is characterized in that the thermoplastic resin is sprayed on the back side member by spraying.
Therefore, the thermoplastic resin is uniformly impregnated on the contact surface of the back side member with the base carpet member.
また、請求項１０に記載した発明にあっては、自動車のフロアパネル上に敷設された下地用カーペット部材上に載置され、カーペット地側基布と、上記カーペット地側基布の表面側から植設されたパイルとからなるカーペット地と、上記カーペット地の裏面側に接合された不織布からなる裏面側部材とを備え、上記裏面側部材をニードルパンチ加工により作成する車載用カーペットの製造方法であって、不織布の搬送方向に沿って設けられた針列が、搬送方向に直交する方向に沿って複数列設けられ、互いに隣接する列においては、上記針が搬送方向に沿った針間隔寸法の半分の距離寸法分、搬送方向においてずれて配設された多数のニードルパンチ針を備えたニードルパンチ加工装置により、順次、ニードルパンチ針を所定寸法を置いて、搬送される上記不織布に対して刺突する第一刺突工程と、その後、上記不織布を、上記第一刺突工程において刺突した針の、各列における隣接する針の、搬送方向における間隔寸法の半分の距離寸法分搬送させた後、上記ニードルパンチ針を刺突することにより、当該第一刺突工程において刺突されたニードルパンチ部に隣接した新たなニードルパンチ部を形成することにより、搬送方向に対して直交する方向に細畝を形成する第二刺突工程とを有することを特徴とする。 Further, in the invention described in claim 10, the carpet is placed on a base carpet member laid on a floor panel of an automobile, and the carpet ground side base cloth and the surface side of the carpet ground side base cloth are used. A method for manufacturing an on-vehicle carpet, comprising: a carpet area made of planted pile; and a back surface side member made of a nonwoven fabric bonded to the back surface side of the carpet area, wherein the back surface member is created by needle punching. A plurality of rows of needles provided along the conveyance direction of the nonwoven fabric are provided along a direction orthogonal to the conveyance direction, and in the rows adjacent to each other, the needles have a needle interval dimension along the conveyance direction. By a needle punch processing device provided with a large number of needle punch needles that are arranged in the conveyance direction by a distance of half the distance, the needle punch needles are sequentially placed at predetermined dimensions, The first piercing step for piercing the nonwoven fabric to be fed, and then the spacing dimension in the conveying direction of adjacent needles in each row of the needles pierced with the nonwoven fabric in the first piercing step After conveying the distance dimension of the half, by piercing the needle punch needle, by forming a new needle punch portion adjacent to the needle punch portion pierced in the first piercing step, And a second piercing step for forming a fine ridge in a direction orthogonal to the transport direction.
従って、上記第一の刺突工程と、上記第二の刺突工程によって形成されたニードルパンチ部が搬送方向に対して直交する方向に沿って並列することによって、上記ニードルパンチ加工部の一方面に、搬送方向と直交する方向の細畝が形成される。 Accordingly, the needle punch portion formed by the first piercing step and the second piercing step is arranged in parallel along the direction orthogonal to the transport direction, so that one surface of the needle punch processing portion On the other hand, narrow strips in the direction orthogonal to the transport direction are formed.
また、請求項１１に記載の発明にあっては、上記第一刺突工程、及び第二刺突工程によって、上記不織布に細畝が形成された後、上記不織布の厚さ方向における反細畝側面部に基布の裏面を接合する裏面側部材形成工程と、上記裏面側部材形成工程で形成された裏面側部材の基布の表面に上記カーペット地側基布を接合するカーペット地接合工程とを有することを特徴とする。
従って、請求項１０の工程によって形成されたニードルパンチ加工部に、搬送方向と直交する方向の複数の細畝を有する裏面側部材を備えた、車載用カーペットが提供される。
Moreover, in invention of Claim 11, after a fine wrinkle is formed in the said nonwoven fabric by the said 1st piercing process and the 2nd piercing process, the anti-wax in the thickness direction of the said nonwoven fabric. A back surface side member forming step of bonding the back surface of the base fabric to the side surface portion, and a carpet ground bonding step of bonding the carpet ground side base fabric to the surface of the base fabric of the back surface side member formed in the back surface side member forming step; It is characterized by having.
Therefore, an on-vehicle carpet provided with a back side member having a plurality of fine lines in a direction orthogonal to the conveying direction in the needle punched portion formed by the process of claim 10 is provided.
また、請求項１２に記載の発明にあっては、隣接する針の、搬送方向における間隔寸法の半分の距離寸法は５ｍｍであることを特徴とする。
従って、上記ニードルパンチ加工部に形成される、各細畝の間隔寸法は５ｍｍとなる。
The invention according to claim 12 is characterized in that the distance between the adjacent needles in the transport direction is half a distance dimension of 5 mm.
Therefore, the space dimension of each fine rod formed in the needle punched portion is 5 mm.
また、請求項１３に記載の発明にあっては、上記カーペット地接合工程の後に、上記裏面側部材に熱可塑性樹脂をスプレーによって噴霧する熱可塑性樹脂噴霧工程と、噴霧した上記熱可塑性樹脂を乾燥させる乾燥工程とを更に有することを特徴とする。 In the invention according to claim 13, after the carpet bonding step, the thermoplastic resin spraying step of spraying the thermoplastic resin onto the back side member by spraying, and drying the sprayed thermoplastic resin. And a drying step.
従って、上記熱可塑性樹脂は、上記裏面側部材内部に均一に含浸する。 Therefore, the thermoplastic resin is uniformly impregnated inside the back side member.
請求項１〜５記載の発明にあっては、上記車載用カーペットの裏面側部材の下地用カーペット部材との当接面に、上記下地用カーペット部材上に載置した場合に、車体の幅方向に沿って配置されうる多数の細畝が形成されていることによって、上記細畝の表面の繊維が下地用カーペット部材のパイル内部に侵入して係合し、下地用カーペット部材がタフテッドカーペットの場合であっても、優れた防滑効果を有する車載用カーペットを提供することができる。
また、上記車載用カーペットに車体の前後方向の力が加わった場合であっても、上記細畝が車体の幅方向に沿って複数配置されていることで、車体の前後方向に対しての、上記車載用カーペットの滑動が効果的に防止される。
特に請求項３の発明にあっては、上記細畝は、上記裏面側部材の上記下地用カーペット部材との当接面から突出して形成された密集したリング状の繊維の先端部の軌道から形成されていることから、下地用カーペット部材がいわゆるタフテッドカーペットの場合であっても、上記リング状繊維の中に、上記下地用カーペット部材のパイルの線状繊維が絡んで係合し、いわゆる面ファスナーの原理によって、上記下地用カーペット部材上における上記車載用カーペットの滑動がより強固に防止される。
In the inventions according to claims 1 to 5, when the back surface side member of the on-vehicle carpet is placed on the contact surface with the base carpet member, the width direction of the vehicle body is placed on the base carpet member. By forming a large number of fine stripes that can be disposed along the surface, the fibers on the surface of the fine stripe penetrate into the pile of the base carpet member and engage with each other, and the base carpet member is made of the tufted carpet. Even if it is a case, the vehicle-mounted carpet which has the outstanding slip prevention effect can be provided.
Further, even when a force in the longitudinal direction of the vehicle body is applied to the on-vehicle carpet, a plurality of the fine rods are arranged along the width direction of the vehicle body, The sliding of the on-vehicle carpet is effectively prevented.
In particular, in the invention of claim 3, the fine rod is formed from a track of a tip end portion of a dense ring-shaped fiber formed to protrude from a contact surface of the back surface side member with the base carpet member. because it is, even if the underlying carpet member of the so-called tufted carpets, in the ring-shaped fiber engage entangled linear fibers of the pile of the underlying carpet member, so-called surface Due to the principle of the fastener, the on-vehicle carpet is more securely prevented from sliding on the underlying carpet member.
また、請求項６記載の発明にあっては、裏面側部材の不織布がフェルト材で形成されていることから、走行時の振動等によって発生する騒音が効率的に吸収されるため、請求項１の効果に加え、より高い吸音効果を得ることが可能な車載用カーペットを得ることが可能となる。 In the invention of claim 6, since the non-woven fabric of the back side member is formed of a felt material, noise generated by vibration during traveling is efficiently absorbed. In addition to the above effect, it is possible to obtain an on-vehicle carpet capable of obtaining a higher sound absorption effect.
また、請求項７〜９記載の発明にあっては、上記裏面側部材の上記下地用カーペット部材との当接面には、アクリル系樹脂である、熱可塑性樹脂が含浸されていることから、請求項１の効果に加え、上記熱可塑性樹脂が有する粘性によって、上記車載用カーペットが上記下地用カーペット部材上に、より強固に固定され、上記車載用カーペットの滑動をより効果的に防止可能な車載用カーペットを提供することができる。
特に請求項９に記載した発明にあっては、上記熱可塑性樹脂はスプレーにより、上記裏面側部材に噴霧されていることから、上記熱可塑性樹脂がより均一に含浸され、防滑効果も上記裏面側部材全域で均一となる。
Further, in the inventions according to claims 7 to 9, since the contact surface of the back surface side member with the base carpet member is impregnated with an acrylic resin, a thermoplastic resin, In addition to the effect of claim 1, the vehicular carpet is more firmly fixed on the base carpet member by the viscosity of the thermoplastic resin, and the sliding of the vehicular carpet can be more effectively prevented. An on-vehicle carpet can be provided.
Particularly in the invention described in claim 9, since the thermoplastic resin is sprayed on the back side member by spraying, the thermoplastic resin is more uniformly impregnated, and the anti-slip effect is also provided on the back side. Uniform throughout the member.
また、請求項１０〜１２の発明にあっては、不織布の搬送方向に沿って設けられた針列が、搬送方向に直交する方向に沿って複数列設けられ、互いに隣接する列においては、上記針が搬送方向に沿った針間隔寸法の半分の距離寸法分、搬送方向においてずれて配設された多数のニードルパンチ針を備えたニードルパンチ加工装置により、順次、ニードルパンチ針を所定寸法を置いて、搬送される上記不織布に対して刺突する第一刺突工程と、その後、上記不織布を、上記第一刺突工程において刺突した針の、各列における隣接する針の、搬送方向における間隔寸法の半分の距離寸法分搬送させた後、上記ニードルパンチ針を刺突することにより、当該第一刺突工程において刺突されたニードルパンチ部に隣接した新たなニードルパンチ部を形成することにより、搬送方向に対して直交する方向に細畝を形成する第二刺突工程とを有することから、一回の刺突に動作間に搬送されるニードルパンチ加工部の寸法を、搬送方向における同一針列において互いに隣接する上記ニードルパンチ針の間隔寸法の半分となるように調整することによって、一般的なニードルパンチ加工装置に改造を加えることなく、上記ニードルパンチ加工部に、搬送方向に対して直交する方向の細畝形状を容易に形成することが可能となる。
また、請求項１１に示すように、第二の刺突工程後に、上記ニードルパンチ加工部の厚さ方向における反細畝側面部に基布の裏面を接合する裏面側部材形成工程と、上記裏面側部材形成工程で形成された裏面側部材の基布の表面に上記カーペット地側基布を接合するカーペット地接合工程を有することによって、裏面側部材と下地用カーペット部材との当接面に、車体の幅方向に沿って配置された多数の細畝を有する車載用カーペットを容易に提供することが可能となる。
Moreover, in invention of Claims 10-12, the needle row | line | column provided along the conveyance direction of a nonwoven fabric is provided in multiple rows | lines along the direction orthogonal to a conveyance direction, and in the row | line | column adjacent to each other, The needle punch needles are sequentially placed at a predetermined dimension by a needle punch processing device having a number of needle punch needles arranged so as to be displaced in the transport direction by a distance of half the needle interval along the transport direction. A first piercing step for piercing the nonwoven fabric to be transported, and then the needles that pierced the nonwoven fabric in the first piercing step, in adjacent rows in each row, in the transport direction After carrying the distance dimension half of the interval dimension, the needle punch needle is pierced to form a new needle punch section adjacent to the needle punch section pierced in the first piercing step. And a second piercing step that forms a fine ridge in a direction perpendicular to the conveying direction, so that the dimensions of the needle punched portion conveyed during the operation to one pierced portion are conveyed. In the same needle row in the direction, it is adjusted so that it is half of the interval between the needle punch needles adjacent to each other. It becomes possible to easily form a narrow shape in a direction orthogonal to the direction.
Moreover, as shown in claim 11, after the second piercing step, the back side member forming step of joining the back side of the base fabric to the anti-thin wrinkle side portion in the thickness direction of the needle punched portion, and the back side By having a carpet ground joining step of joining the carpet ground side base fabric to the surface of the base fabric of the back side member formed in the side member forming step, on the contact surface between the back side member and the base carpet member, It is possible to easily provide an on-vehicle carpet having a large number of fine lines arranged along the width direction of the vehicle body.
また、請求項１３の発明にあっては、上記裏面側部材に噴霧された熱可塑性樹脂の有する粘性によって、上記裏面側部材の上記下地用カーペット部材との当接面が上記下地用カーペット部材に接着固定されるため、上記下地用カーペット上でより滑動しにくい車載用カーペットを提供することができる。 In the invention of claim 13, due to the viscosity of the thermoplastic resin sprayed on the back side member, the contact surface of the back side member with the base carpet member becomes the base carpet member. Since it is bonded and fixed, it is possible to provide an on-vehicle carpet that is less likely to slide on the underlying carpet.
以下、裏面側部材のニードルパンチ加工部がフェルト材で形成されており、且つ、上記裏面側部材に含浸させる熱可塑性樹脂がアクリル系樹脂である場合を例として本発明の実施の形態を図面を用いて説明する。
（１）車載用カーペット
図１に示すように、本実施の形態に係る車載用カーペット１０は、自動車のフロアパネル上に敷設された下地用カーペット部材１１上に載置され、カーペット地側基布１２と、上記カーペット地側基布１２の表面側から植設されたパイル１３とからなるカーペット地１４と、上記カーペット地１４の裏面側に接合された、フェルト材である不織布からなる裏面側部材１５とを備えている。
図２に示すように、上記裏面側部材１５の上記下地用カーペット部材１１との当接面１６には、上記下地用カーペット部材１１上に載置した場合に、車体の幅方向（即ち、図２における紙面垂直方向）に沿って配置されうる多数の細畝１７が形成されている。
上記裏面側部材１５は、上記カーペット地側基布１２に接合された基布１９と、上記基布１９の裏面側に接合され、上記下地用カーペット部材１１に当接する不織布からなるニードルパンチ加工部２０とからなり、上記細畝１７は、図３に示すように、複数のニードルパンチ用針２１を上記不織布２０に刺突することにより形成され、上記複数のニードルパンチ用針２１は、上記不織布２０の搬送方向に沿って配置された針列２２ａ、２２ｂ、２２ｃ、２２ｄ、２２ｅ、２２ｆ、２２ｇ、２２ｈ、２２ｉ、２２ｊ、２２ｋ、２２Ｌ、２２ｍが搬送方向に直交する方向に沿って設けられ、相互に隣接する針列（例えば２２ａと２２ｂ）は、１０ｍｍに形成された搬送方向に沿った一対の針の間隔寸法Ｐの、半分の５ｍｍに形成された間隔寸法Ｑ分、搬送方向において互いにずれて設けられている。
また、図２に示すように、上記細畝１７は、密集したリング状の繊維２３が突出して形成されている。
また、上記細畝１７は、図１及び図３に示すように、上記不織布２０の搬送方向に沿った針列における直近の２つのニードルパンチ用針２１（図２には図示せず）の間隔寸法Ｐの半分の間隔寸法Ｑをおいて形成されている。
また、図２に示すように、上記裏面側部材１５の上記下地用カーペット部材１１との当接面１６には、アクリル系樹脂である熱可塑性樹脂２４がスプレーによって噴霧されることによって含浸されている。
（２）車載用カーペットの製造方法
本実施の形態に係る車載用カーペット１０の製造方法は、図３に示すように、
不織布２０の搬送方向Ａに沿って設けられた針列２２ａ、２２ｂ、２２ｃ、２２ｄ、２２ｅ、２２ｆ、２２ｇ、２２ｈ、２２ｉ、２２ｊ、２２ｋ、２２Ｌ、２２ｍが、搬送方向Ａに直交する方向に沿って設けられ、互いに隣接する列（例えば２２ａと２２ｂ）においては、上記針列（例えば２２ａと２２ｂ）を構成する針２１が、１０ｍｍに形成された搬送方向Ａに沿った針間隔寸法Ｐの、半分の５ｍｍに形成された距離寸法Ｑ分、搬送方向Ａにおいてずれて配設された、多数のニードルパンチ針２１を備えたニードルパンチ加工装置２５により、図４に示すように順次、ニードルパンチ針２１を所定寸法Ｑを置いて、搬送される上記不織布２０に対して刺突する第一刺突工程２６と、その後、上記不織布２０を、上記第一刺突工程２０において刺突した針２１の、各列における隣接する針２１の、搬送方向Ａにおける間隔寸法Ｐの半分の距離寸法Ｑ分搬送させた後、上記ニードルパンチ針２１を刺突することにより、当該第一刺突工程２６において刺突されたニードルパンチ部２８ａに隣接した新たなニードルパンチ部２８ｂを形成することにより、搬送方向Ａに対して直交する方向に細畝１７を形成する第二刺突工程２７とを有している。
また、上記第一刺突工程２６、及び第二刺突工程２７によって、上記不織布２０に細畝１７が形成された後、図５に示すように上記不織布２０の厚さ方向における反細畝側面部２９に基布１９の裏面を接合する裏面側部材形成工程３０と、上記裏面側部材形成工程３０で形成された裏面側部材１５の基布１９の表面に上記カーペット地側基布１２を接合するカーペット地接合工程３１とを有している。
また、図５に示すように、上記カーペット地接合工程３１の後に、上記裏面側部材１５にアクリル樹脂である熱可塑性樹脂２４をスプレー（図示せず）によって噴霧する熱可塑性樹脂噴霧工程３２と、噴霧した上記熱可塑性樹脂２４を乾燥させる乾燥工程３３とを更に有している。
Hereinafter, the embodiment of the present invention will be described with reference to an example in which the needle punched portion of the back side member is formed of a felt material and the thermoplastic resin impregnated in the back side member is an acrylic resin. It explains using.
(1) Car-mounted carpet As shown in FIG. 1, the vehicle-mounted carpet 10 according to the present embodiment is placed on a base carpet member 11 laid on a floor panel of an automobile, and the carpet base fabric. 12 and a carpet 13 made of a pile 13 planted from the surface side of the carpet base fabric 12 and a back side member made of a nonwoven fabric made of a felt material joined to the back side of the carpet base 14. 15.
As shown in FIG. 2, when the back surface side member 15 is placed on the ground carpet member 11 on the contact surface 16 of the back surface side member 15 with the ground carpet member 11, the width direction of the vehicle body (that is, FIG. 2 are formed along the vertical direction of the paper surface in FIG.
The back side member 15 includes a base fabric 19 joined to the carpet ground side base fabric 12 and a needle punched portion made of a nonwoven fabric joined to the back side of the base fabric 19 and abutted against the base carpet member 11. As shown in FIG. 3, the fine scissors 17 are formed by inserting a plurality of needle punch needles 21 into the nonwoven fabric 20, and the plurality of needle punch needles 21 are formed of the nonwoven fabric. 20 needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, and 22m arranged along the carrying direction are provided along the direction orthogonal to the carrying direction, The needle rows adjacent to each other (for example, 22a and 22b) have a distance dimension Q formed at half of 5 mm of the distance P between the pair of needles along the conveying direction formed at 10 mm. , It is provided offset from each other in the transport direction.
As shown in FIG. 2, the fine rod 17 is formed by protruding dense ring-shaped fibers 23.
Further, as shown in FIGS. 1 and 3, the fine wrinkle 17 is a distance between the two nearest needle punch needles 21 (not shown in FIG. 2) in the needle row along the conveyance direction of the nonwoven fabric 20. It is formed with an interval dimension Q that is half of the dimension P.
Further, as shown in FIG. 2, the contact surface 16 of the back surface side member 15 with the base carpet member 11 is impregnated by spraying a thermoplastic resin 24 which is an acrylic resin by spraying. Yes.
(2) Method for Manufacturing Car Carpet The method for manufacturing the car carpet 10 according to the present embodiment is as shown in FIG.
The needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, and 22m provided along the conveyance direction A of the nonwoven fabric 20 are along the direction orthogonal to the conveyance direction A. In the rows adjacent to each other (for example, 22a and 22b), the needles 21 constituting the needle row (for example, 22a and 22b) have a needle interval dimension P along the conveyance direction A formed at 10 mm. As shown in FIG. 4, the needle punch needles are sequentially formed by a needle punch processing device 25 having a large number of needle punch needles 21 arranged in a transfer direction A by a distance dimension Q of half of 5 mm. The first piercing step 26 for piercing the nonwoven fabric 20 to be conveyed with a predetermined dimension Q, and then the nonwoven fabric 20 into the first piercing step 20 After the needle 21 that has been pierced is conveyed by a distance dimension Q that is half the interval dimension P in the conveyance direction A of the adjacent needle 21 in each row, the needle punch needle 21 is pierced, thereby A second piercing step for forming the fine punch 17 in a direction orthogonal to the conveying direction A by forming a new needle punching portion 28b adjacent to the needle punching portion 28a pierced in the one piercing step 26 27.
Moreover, after the fine candy 17 is formed in the said nonwoven fabric 20 by the said 1st piercing process 26 and the 2nd piercing process 27, as shown in FIG. 5, the anti-fine ridge side surface in the thickness direction of the said nonwoven fabric 20 is shown. The back side member forming step 30 for joining the back side of the base fabric 19 to the portion 29, and the carpet base side fabric 12 is joined to the surface of the base fabric 19 of the back side member 15 formed in the back side member forming step 30. And carpet carpet joining step 31.
Further, as shown in FIG. 5, after the carpet bonding step 31, a thermoplastic resin spraying step 32 for spraying the thermoplastic resin 24, which is an acrylic resin, on the back surface side member 15 by spraying (not shown), And a drying step 33 for drying the sprayed thermoplastic resin 24.
上記実施例の構成による車載用カーペットの実施例について図面を用いて詳述する。
図１は、本実施例の構成における車載用カーペット１０の断面図である。
上記車載用カーペット１０は、カーペット地１４と裏面側部材１５とが熱溶着等の手段によって圧着接合されて形成されている。
カーペット地１４はカーペット地側基布１２にパイル１３がタフトされて形成された、いわゆるタフテッドカーペットである。
また、裏面側部材１５は、フェルト材からなる不織布で形成されたニードルパンチ加工部２０の表面部に基布１９が圧着接合されて形成されており、上記裏面側部材１５と上記カーペット地１４とは、接着剤を介して圧着固定され、上記車載用カーペット１０を構成している。
また、図２は上記車載用カーペット１０を、フロアパネル１８上に敷設された、タフテッドカーペットである下地用カーペット部材１１上に載置した状態の断面図、及び上記車載用カーペット１０の裏面側部材１５の細畝１７と上記下地用カーペット部材１１のパイル３６との接合部分の拡大断面図である。
上記下地用カーペット部材は、基布３４に線状の繊維３５が密集して形成されたパイル３６がタフトされて形成されている。
上記車載用カーペット１０を上記下地用カーペット部材１１上に載置した場合、上記細畝１７が矢印Ｂに示す車体の前後方向に対して直交する方向に配置されていることから、上記細畝１７が上記下地用カーペット部材１１のパイル３６に圧接して、上記パイル３６内に侵入することによる摩擦力と、上記下地用カーペット部材１１のパイル３６を構成する線状繊維３５が、上記細畝１７を構成する密集したリング状の繊維２３に絡みつき、いわゆる面ファスナーの原理によって係合する接着力によって、上記車載用カーペット１０は上記下地用カーペット部材１１上において強固に固定されるため、上記下地用カーペット部材１１が、いわゆるタフテッドカーペットで形成されている場合であっても、上記車載用カーペット１０の滑動を効果的に防止することができる。
また、図１に示すように、上記ニードルパンチ加工部２０にはアクリル系樹脂である熱可塑性樹脂２４が含浸されていることから、上記熱可塑性樹脂２４が有する粘性による接着作用によって、上記車載用カーペット１０と上記下地用カーペット部材１１とがより強固に接合され、滑動防止効果を更に高めることが可能となる。
Embodiments of the on-vehicle carpet having the configuration of the above embodiment will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional view of an on-vehicle carpet 10 in the configuration of this embodiment.
The on-vehicle carpet 10 is formed by pressure-bonding a carpet base 14 and a back surface side member 15 by means such as heat welding.
The carpet base 14 is a so-called tufted carpet formed by tufting a pile 13 on the carpet base fabric 12.
The back side member 15 is formed by pressure bonding the base fabric 19 to the surface portion of the needle punched portion 20 formed of a nonwoven fabric made of felt material, and the back side member 15 and the carpet base 14 Is fixed by pressure bonding with an adhesive, and constitutes the on-vehicle carpet 10.
2 is a cross-sectional view of the vehicle-mounted carpet 10 placed on a ground carpet member 11 that is a tufted carpet laid on the floor panel 18, and the back side of the vehicle-mounted carpet 10. FIG. 4 is an enlarged cross-sectional view of a joint portion between a fine rod 17 of a member 15 and a pile 36 of the base carpet member 11.
The base carpet member is formed by tufting a pile 36 in which linear fibers 35 are densely formed on a base fabric 34.
When the on-vehicle carpet 10 is placed on the underlying carpet member 11, the fine lines 17 are arranged in a direction orthogonal to the front-rear direction of the vehicle body indicated by the arrow B. Is pressed against the pile 36 of the underlying carpet member 11 and enters the pile 36, and the linear fibers 35 constituting the pile 36 of the underlying carpet member 11 are formed by the fine mesh 17. The in-vehicle carpet 10 is firmly fixed on the base carpet member 11 by the adhesive force that is entangled with the dense ring-shaped fibers 23 constituting the base and is engaged by the principle of a so-called hook-and-loop fastener. Even when the carpet member 11 is formed of a so-called tufted carpet, the sliding of the in-car carpet 10 is effective. It is possible to prevent manner.
Further, as shown in FIG. 1, since the needle punched portion 20 is impregnated with a thermoplastic resin 24 which is an acrylic resin, the above-mentioned in-vehicle use is performed by an adhesive action due to the viscosity of the thermoplastic resin 24. The carpet 10 and the base carpet member 11 are more firmly joined, and the sliding prevention effect can be further enhanced.
上記実施例の構成による車載用カーペットの製造方法の実施例について図面を用いて詳述する。
図３は、上記車載用カーペット１０の裏面側部材１５のニードルパンチ加工部２０に細畝１７を形成させるためのニードルパンチ加工装置２５の側面図及び平面図を概念的に示している。
上記ニードルパンチ加工装置２５は所定長を有する長方形板状の台座部３７に複数のニードルパンチ用針２１が配置されて形成されている。
上記ニードルパンチ用針２１は、搬送方向に沿って配置された針列２２ａ、２２ｂ、２２ｃ、２２ｄ、２２ｅ、２２ｆ、２２ｇ、２２ｈ、２２ｉ、２２ｊ、２２ｋ、２２Ｌ、２２ｍを形成し、上記針列２２ａ〜２２ｍは搬送方向に対して直交する方向に配置されている。
上記ニードルパンチ用針２１は、同一列において、それぞれ１０ｍｍ（間隔寸法Ｐ）ずつ離間して配置されている。
また、上記ニードルパンチ用針２１は隣接する列間において、搬送方向に対して５ｍｍ（距離寸法Ｑ）ずれて配置されている。
図４は、上記車載用カーペット１０の製造方法における第一刺突工程２６と、第二刺突工程２７における、上記ニードルパンチ加工装置２５の動作説明を示す平面図である。
図４の上段部は、上記第一刺突工程２６における上記ニードルパンチ加工装置２５の動作、下段は上記第二刺突工程２７における上記ニードルパンチ加工装置２５の動作をそれぞれ示している。
図４上段に示すように、帯状に形成された不織布からなるニードルパンチ加工部２０が上記ニードルパンチ加工装置２５上に所定長搬送された時点で、上記第一の刺突工程２６において、上記ニードルパンチ針２１によって上記ニードルパンチ加工部２０が刺突され、針列２２ｂ、２２ｄ、２２ｆ、２２ｈ、２２ｊ、２２Ｌの搬送方向において同一位置にあるニードルパンチ針２１によって、ニードルパンチ部２８ａが形成される。
その後、図４下段に示すように、上記第二の刺突工程２７において、帯状に形成された上記ニードルパンチ加工部２０は、搬送方向に沿って距離寸法Ｑ（５ｍｍ）搬送され、再度上記ニードルパンチ針２１によって上記ニードルパンチ加工部２０が刺突される。
この際、針列２２ａ、２２ｃ、２２ｅ、２２ｇ、２２ｉ、２２ｋ、２２ｍの搬送方向において同一位置にあるニードルパンチ針２１によって、ニードルパンチ部２８ｂが、上記第一刺突工程２６において形成されたニードルパンチ部２８ａに隣接して形成される。
上記第一刺突工程２６と第二刺突工程２７が所定回数繰り返されることによって、上記ニードルパンチ加工部２０には、距離寸法Ｑ（５ｍｍ）間隔毎に、上記ニードルパンチ部２８ａ、２８ｂによって、搬送方向に直交する方向に細畝１７が形成される。
その後、図５に示すように上記裏面側部材形成工程３０において、上記第一刺突工程２６と第二刺突工程２７によって細畝１７が形成されたニードルパンチ加工部２０の厚さ方向における反細畝側面に基布１９が熱圧着手段等によって接合された後、上記カーペット地接合手段３１において、接着剤等を介して、上記基布１９の表面にカーペット地１４が接合される。
その後、熱可塑性樹脂噴霧工程３２において、上記裏面側部材１５のニードルパンチ加工部２０に対して、スプレーによってアクリル系樹脂である熱可塑性樹脂２４が噴霧され、乾燥工程３３によって、熱可塑性樹脂２４を乾燥させることによって、上記車載用カーペット１０が完成する。
本方法によれば、一回の刺突動作の間に搬送されるニードルパンチ加工部２０の寸法を、同一針列において互い隣接する上記ニードルパンチ針２１の間隔寸法Ｐの半分（距離寸法Ｑ）となるように調整することによって、一般的なニードルパンチ加工装置に改造を加えることなく、上記ニードルパンチ加工部２０に、搬送方向に対して直交する方向の細畝１７を容易に形成することが可能となる。
An embodiment of a method for manufacturing an on-vehicle carpet having the configuration of the above embodiment will be described in detail with reference to the drawings.
FIG. 3 conceptually shows a side view and a plan view of a needle punch processing device 25 for forming the fine punch 17 in the needle punch processing portion 20 of the back side member 15 of the on-vehicle carpet 10.
The needle punch processing device 25 is formed by arranging a plurality of needle punch needles 21 on a rectangular plate-shaped pedestal portion 37 having a predetermined length.
The needle punch needle 21 forms needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, and 22m arranged along the transport direction. 22a-22m are arrange | positioned in the direction orthogonal to a conveyance direction.
The needle punch needles 21 are spaced apart by 10 mm (interval dimension P) in the same row.
Further, the needle punch needles 21 are arranged so as to be shifted by 5 mm (distance dimension Q) with respect to the conveying direction between adjacent rows.
FIG. 4 is a plan view illustrating the operation of the needle punch processing device 25 in the first piercing step 26 and the second piercing step 27 in the method for manufacturing the on-vehicle carpet 10.
4 shows the operation of the needle punch processing device 25 in the first piercing step 26, and the lower portion shows the operation of the needle punch processing device 25 in the second piercing step 27, respectively.
As shown in the upper part of FIG. 4, when the needle punching portion 20 made of a non-woven fabric formed in a belt shape is conveyed onto the needle punching device 25 for a predetermined length, in the first piercing step 26, the needle The needle punching portion 20 is pierced by the punch needle 21, and the needle punch portion 28a is formed by the needle punch needle 21 at the same position in the conveying direction of the needle rows 22b, 22d, 22f, 22h, 22j, and 22L. .
Thereafter, as shown in the lower part of FIG. 4, in the second piercing step 27, the needle punching portion 20 formed in a band shape is conveyed by a distance dimension Q (5 mm) along the conveying direction, and again the needle The needle punching portion 20 is pierced by the punch needle 21.
At this time, the needle punch portion 28b is formed in the first piercing step 26 by the needle punch needle 21 at the same position in the conveying direction of the needle rows 22a, 22c, 22e, 22g, 22i, 22k, 22m. It is formed adjacent to the punch portion 28a.
By repeating the first piercing step 26 and the second piercing step 27 a predetermined number of times, the needle punching portion 20 is provided with the needle punch portions 28a and 28b at intervals of the distance dimension Q (5 mm). A narrow rod 17 is formed in a direction orthogonal to the conveying direction.
Thereafter, as shown in FIG. 5, in the back side member forming step 30, the needle punched portion 20 in which the fine punches 17 are formed by the first piercing step 26 and the second piercing step 27 is counteracted in the thickness direction. After the base cloth 19 is bonded to the side surfaces of the fine ridges by a thermocompression bonding means or the like, the carpet cloth bonding means 31 bonds the carpet cloth 14 to the surface of the base cloth 19 via an adhesive or the like.
Thereafter, in the thermoplastic resin spraying step 32, the thermoplastic resin 24, which is an acrylic resin, is sprayed on the needle punched portion 20 of the back side member 15 by spraying, and the thermoplastic resin 24 is sprayed by the drying step 33. The in-car carpet 10 is completed by drying.
According to this method, the dimension of the needle punch processing unit 20 conveyed during one piercing operation is set to half the distance dimension P of the needle punch needles 21 adjacent to each other in the same needle row (distance dimension Q). By adjusting so as to be, the fine punch 17 in the direction perpendicular to the conveying direction can be easily formed in the needle punching portion 20 without modifying a general needle punching device. It becomes possible.
ところで、上記カーペット地１４のパイル１３は所定の方向に僅かに傾斜しており、傾斜する方向を順目と称し、その逆方向を逆目と称している。
図５に示す上記カーペット地接合工程３１において、カーペット地１４を上記裏面側部材１５に接合する場合、一般的に、上記カーペット地１４のパイル１３が搬送法方向に対して順目若しくは逆目となるよう接合する。
また、完成した車載用カーペット１０を車室内に敷設する場合、乗員の視覚による外観品質向上を目的として、一般的には、車体の進行方向に対して上記パイル１３が順目、若しくは逆目となるように敷設する。
本製造方法によらずに、一般的なニードルパンチ加工工程によって畝を形成させた場合は、ニードルパンチ加工における搬送方向に沿った形状の畝となる。
従って、形成された畝の幅方向とパイルの目の傾斜方向とは、互いに直交することから、上記畝が車体の幅方向となるように車載用カーペットを敷設した場合には、上記パイルは車体の幅方向一方側に傾斜した状態となり、パイルの順目若しくは逆目方向から視認した場合とパイルの視覚上の色彩が変化し、乗員の視覚による外観品質が低下する。
これに対し、本実施例に示す製造方法によれば、図５に示すように、上記カーペット地接合工程３１において、上記パイル１３が搬送方向に対して順目若しくは逆目となる状態で、上記裏面側部材１５に接合され、且つ上記細畝１７が上記十面目、逆目方向に対して略直交するように接合されて、搬送方向に直交する方向に沿って形成された上記細畝１７の各列が搬送方向に沿って並列するため、パイル１３の目の傾斜方向と、上記細畝１７の並列方向が一致する。
従って、カーペット地１４を接合した後に、所定寸法に裁断することによって、車体の幅方向に沿って上記細畝１７の各列が並列して配置されるように敷設した場合に、パイル１３の目は、車体の進行方向に対して、順目若しくは逆目の状態となり、外観品質に優れた車載用カーペット１０を、ニードルパンチ加工装置の構成を変更することなく、ニードルパンチ加工時の搬送速度を適宜に調整するのみで容易に製造可能となるという効果をも呈する。
By the way, the pile 13 of the carpet ground 14 is slightly inclined in a predetermined direction, and the direction in which the pile 13 is inclined is referred to as “forward”, and the opposite direction is referred to as “inverse”.
In the carpet ground joining step 31 shown in FIG. 5, when the carpet ground 14 is joined to the back surface side member 15, generally, the pile 13 of the carpet ground 14 is either forward or reverse with respect to the conveyance method direction. Join to become.
In addition, when the completed vehicle-mounted carpet 10 is laid in the passenger compartment, generally, the pile 13 is arranged in a normal or reverse direction with respect to the traveling direction of the vehicle body for the purpose of improving the visual quality of the passenger. Lay so that.
Regardless of the manufacturing method, when the ridge is formed by a general needle punching process, the ridge has a shape along the conveying direction in the needle punching process.
Therefore, since the width direction of the formed ridge and the inclination direction of the pile eyes are orthogonal to each other, when the vehicle-mounted carpet is laid so that the ridge is in the width direction of the vehicle body, the pile is In this case, the visual color of the pile is changed from that when viewed from the direction of the order of the pile or the direction of the reverse of the pile, and the visual appearance quality of the occupant is deteriorated.
On the other hand, according to the manufacturing method shown in the present embodiment, as shown in FIG. 5, in the carpet ground joining step 31, the pile 13 is in a state of being forward or reverse with respect to the conveying direction. The fine rod 17 is joined to the back side member 15 and the fine rod 17 is joined so as to be substantially orthogonal to the tenth and reverse directions, and is formed along the direction perpendicular to the conveying direction. Since each row is arranged in parallel along the conveying direction, the direction of inclination of the eyes of the pile 13 and the direction in which the fine rods 17 are aligned coincide.
Therefore, when the carpets 14 are joined and then cut into a predetermined size, the piles 13 are arranged when the rows of the thin rods 17 are arranged in parallel along the width direction of the vehicle body. The vehicle-carpet 10 that is in a normal or reverse state with respect to the traveling direction of the vehicle body and has excellent appearance quality can be transported at a needle punching speed without changing the configuration of the needle punching apparatus. There is also an effect that it can be easily manufactured only by adjusting appropriately.
本発明は自動車等の車室内に敷設される車載用カーペット及びその製造方法に適用することが可能である。 The present invention can be applied to an on-vehicle carpet laid in a passenger compartment of an automobile or the like and a method for manufacturing the same.
１０ 車載用カーペット
１１ 下地用カーペット部材
１２ カーペット地側基布
１３ パイル
１４ カーペット地
１５ 裏面側部材
１６ 裏面側部材の下地用カーペット部材との当接面
１７ 細畝
１８ フロアパネル
１９ 基布
２０ ニードルパンチ加工部（不織布）
２１ ニードルパンチ針
２２ａ 針列
２２ｂ 針列
２２ｃ 針列
２２ｄ 針列
２２ｅ 針列
２２ｆ 針列
２２ｇ 針列
２２ｈ 針列
２２ｉ 針列
２２ｊ 針列
２２ｋ 針列
２２Ｌ 針列
２２ｍ 針列
２３ 細畝のリング状繊維
２４ 熱可塑性樹脂
２５ ニードルパンチ加工装置
２６ 第一刺突工程
２７ 第二刺突工程
２８ａ ニードルパンチ部
２８ｂ ニードルパンチ部
２９ ニードルパンチ加工部の厚さ方向における反細畝側面部
３０ 裏面側部材形成工程
３１ カーペット地接合工程
３２ 熱可塑性樹脂噴霧工程
３３ 乾燥工程
３４ 下地用カーペット部材の基布
３５ 下地用カーペット部材のパイルの線状繊維
３６ 下地用カーペット部材のパイル
３７ 台座部
７０ 車載用カーペット
７１ 素材
７２ 弾性層
７３ 弾性層の下面
７４ 防滑用突起
７５ 防滑用突起の台座部
７６ スパイク状突起
８０ 車載用カーペット
８１ 表面材
８２ 裏面材
８３ 繊維
８４ 樹脂塊
DESCRIPTION OF SYMBOLS 10 Car-mounted carpet 11 Ground carpet member 12 Carpet ground side base cloth 13 Pile 14 Carpet ground 15 Back surface side member 16 The contact surface 17 of the back surface side member with the base carpet member 17 Fine tile 18 Floor panel 19 Base cloth 20 Needle punch Processing part (nonwoven fabric)
21 Needle punch needle 22a Needle row 22b Needle row 22c Needle row 22d Needle row 22e Needle row 22g Needle row 22h Needle row 22i Needle row 22j Needle row 22k Needle row 22L Needle row 22m Needle row 23 24 Thermoplastic resin 25 Needle punch processing device 26 First piercing step 27 Second piercing step 28a Needle punch portion 28b Needle punch portion 29 Anti-thin side surface portion 30 in the thickness direction of the needle punch portion Back surface side member forming step 31 Carpeting step 32 Thermoplastic resin spraying step 33 Drying step 34 Base carpet member base cloth 35 Pile linear fiber 36 base carpet member pile 37 Pedestal portion 70 Car-mounted carpet 71 Material 72 Elastic layer 73 Lower surface 74 of elastic layer Anti-slip protrusion 75 Base part 76 of anti-slip protrusion Spike Protrusion 80 Carpet 81 for vehicle use Surface material 82 Back material 83 Fiber 84 Resin lump
Claims (13)
上記裏面側部材の上記下地用カーペット部材との当接面には、上記下地用カーペット部材上に載置した場合に、車体の幅方向に沿って配置されうる多数の細畝が形成されていることを特徴とする車載用カーペット。 A carpet ground, which is placed on a base carpet member laid on a floor panel of an automobile and includes a carpet base fabric and a pile planted from the surface side of the carpet base base fabric, and the carpet It is an on-vehicle carpet provided with a back side member made of a nonwoven fabric bonded to the back side of the ground,
On the contact surface of the back side member with the base carpet member, there are formed a large number of fine lines that can be arranged along the width direction of the vehicle body when placed on the base carpet member. Car-mounted carpet characterized by that.
上記細畝は、複数のニードルパンチ用針を上記不織布に刺突することにより形成され、
上記複数のニードルパンチ用針は、不織布の搬送方向に沿って配置された針列が搬送方向に直交する方向に複数設けられ、
相互に隣接する針列は、搬送方向に沿った一対の針の間隔寸法の半分の間隔寸法分、搬送方向において互いにずれて設けられていることを特徴とする請求項１記載の車載用カーペット The back side member is composed of a base fabric joined to the carpet ground side base fabric, and a needle punched portion made of a non-woven fabric joined to the back side of the base fabric and in contact with the base carpet member,
The fine rod is formed by piercing the nonwoven fabric with a plurality of needle punch needles,
The plurality of needle punch needles, a plurality of needle rows arranged along the direction of conveyance of the nonwoven fabric is provided in a direction perpendicular to the direction of conveyance,
2. The on-vehicle carpet according to claim 1, wherein the adjacent needle rows are provided so as to be shifted from each other in the transport direction by a distance of half the distance between the pair of needles along the transport direction.
不織布の搬送方向に沿って設けられた針列が、搬送方向に直交する方向に沿って複数列設けられ、互いに隣接する列においては、上記針列を構成する針が搬送方向に沿った針間隔寸法の半分の距離寸法分、搬送方向においてずれて配設された多数のニードルパンチ針を備えたニードルパンチ加工装置により、順次、ニードルパンチ針を所定寸法を置いて、搬送される上記不織布に対して刺突する第一刺突工程と、
その後、上記不織布を、上記第一刺突工程において刺突した針の、各列における隣接する針の、搬送方向における間隔寸法の半分の距離寸法分搬送させた後、上記ニードルパンチ針を刺突することにより、当該第一刺突工程において刺突されたニードルパンチ部に隣接した新たなニードルパンチ部を形成することにより、搬送方向に対して直交する方向に細畝を形成する第二刺突工程とを有することを特徴とする車載用カーペットの製造方法。 A carpet ground, which is placed on a base carpet member laid on a floor panel of an automobile and includes a carpet base fabric and a pile planted from the surface side of the carpet base base fabric, and the carpet A backside member made of a nonwoven fabric bonded to the backside of the ground, and a method for manufacturing an on-vehicle carpet for creating the backside member by needle punching,
A plurality of rows of needles provided along the conveyance direction of the nonwoven fabric are provided along a direction orthogonal to the conveyance direction, and in the rows adjacent to each other, the needles constituting the needle rows are spaced apart along the conveyance direction. The needle punch needle is provided with a number of needle punch needles arranged at a distance of half the dimension and shifted in the transport direction, and the needle punch needles are sequentially placed with a predetermined dimension on the transported nonwoven fabric. A first piercing step to pierce and
Thereafter, the non-woven fabric is conveyed by a distance of half the distance between the adjacent needles in each row of the needle pierced in the first piercing step, and then the needle punch needle is pierced. By forming a new needle punch portion adjacent to the needle punch portion pierced in the first piercing step, a second piercing portion that forms a fine ridge in a direction orthogonal to the conveying direction And a process for producing an in-vehicle carpet.
上記裏面側部材形成工程で形成された裏面側部材の基布の表面に上記カーペット地側基布を接合するカーペット地接合工程とを有することを特徴とする請求項１０に記載の車載用カーペットの製造方法。 The first barbs collision process, and by a second puncturing collision process, after Hosose is formed on the nonwoven fabric, the back side member joining the rear surface of the base fabric in a counter Hosose side portion in the thickness direction of the nonwoven fabric forming Process,
The carpet base bonding step according to claim 10, further comprising: a carpet base joining step for joining the carpet base base fabric to a surface of the base fabric of the back side member formed in the back side member forming step. Production method.
The thermoplastic resin spraying step of spraying a thermoplastic resin onto the back side member by spraying after the carpet bonding step, and a drying step of drying the sprayed thermoplastic resin. 11. A method for producing an on-vehicle carpet according to 11.
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| JP2008183835A JP4712840B2 (en) | 2008-07-15 | 2008-07-15 | Car-mounted carpet and method for manufacturing the same |
| US12/205,360 US20100015384A1 (en) | 2008-07-15 | 2008-09-05 | Vehicle mounting carpet and producing method thereof |
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| JP2008183835A JP4712840B2 (en) | 2008-07-15 | 2008-07-15 | Car-mounted carpet and method for manufacturing the same |
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| JP4712840B2 true JP4712840B2 (en) | 2011-06-29 |
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| AT510458B1 (en) * | 2010-09-17 | 2013-08-15 | Intier Automotive Eybl Ges M B H Ebergassing & Co Ohg | COATING COMPOSITION FOR THE SOUND REDUCING CLADDING OF A MOTOR VEHICLE AREA AND METHOD FOR THE PRODUCTION THEREOF |
| JP5713656B2 (en) * | 2010-12-16 | 2015-05-07 | ヨシミツ毛織株式会社 | Car interior carpet, automobile, and joint structure of interior carpet and floor mat |
| KR101666195B1 (en) * | 2015-05-06 | 2016-10-13 | 주식회사 하도에프앤씨 | Car mat and manufacturing method of thereof |
| CN104970669B (en) * | 2015-05-30 | 2016-08-31 | 叶金仁 | A kind of preparation method of tufted carpet |
| CN104856544B (en) * | 2015-05-30 | 2016-06-08 | 叶金仁 | A kind of health care tufted carpet |
| CN105231782A (en) * | 2015-11-18 | 2016-01-13 | 张继金 | Method for producing carpet by using waste clothes |
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| US20100015384A1 (en) | 2010-01-21 |
| JP2010022411A (en) | 2010-02-04 |
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