JP5266894B2 - カーペット及びその製造方法 - Google Patents
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- B32B2307/724—Permeability to gases, adsorption
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B2605/08—Cars
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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Description
また、上記特許文献1のカーペットカーペット100では、接着フィルム層102に吸音不織布層103の繊維を貫通させることで通気孔を形成しているため、通気孔の大きさ、個数、配置等を制御することができない。一方、これを解決するために接着フィルム層102に孔あけ処理を施すことも考えられるが、その場合は製造工程が増え生産性が低下する。
さらに、上記特許文献2のカーペット123では、吸音層となる発泡プラスチックシート119が表面に露出しているので、表面側から侵入してきた音は、一旦は発泡プラスチックシート119に入るものの減衰する前に放出されてしまい、吸音性が極めて低い。
1.第1非通気層と、該第1非通気層の裏面側に設けられる吸音層と、該吸音層の裏面側に設けられる第2非通気層と、を備え、
前記第1非通気層及び前記吸音層に貫通し且つ前記第2非通気層に貫通せずにパイル糸を植設してなり、
前記吸音層は、前記第1非通気層の厚さより大きな厚さを有し、
前記吸音層を構成する不織布の繊維の繊度は、前記吸音層の厚みを維持するために2.2〜17デシテックスであることを特徴とするカーペット。
2.前記第1非通気層の表面側に設けられる表皮基材層を更に備え、前記パイル糸は、該表皮基材層、前記第1非通気層及び前記吸音層に貫通し且つ前記第2非通気層に貫通せずに植設されている上記1.記載のカーペット。
3.前記第1非通気層は、前記表皮基材層と前記吸音層とを接着する接着フィルムである上記2.記載のカーペット。
4.前記パイル糸は、前記吸音層の裏面側にU字状に突出している上記1.乃至3.のいずれか一項に記載のカーペット。
5.上記1.乃至4.のいずれか一項に記載のカーペットの製造方法であって、
前記第1非通気層及び前記吸音層を積層して、該吸音層側から該吸音層及び該第1非通気層に貫通して前記パイル糸を植設する第1工程と、
前記パイル糸の植設された前記吸音層の裏面側に前記第2非通気層を積層する第2工程と、を備えることを特徴とするカーペットの製造方法。
また、前記吸音層を構成する不織布の繊維の繊度が2.2〜17デシテックスであるので、吸音層を構成する繊維が比較的太いので、吸音層の厚みを維持することで吸音性能を確保しつつパイル糸を貫通させる際の抵抗が過度に大きくならず生産性をより高めることができる。
また、前記第1非通気層の表面側に設けられる表皮基材層を更に備え、前記パイル糸が、該表皮基材層、前記第1非通気層及び前記吸音層に貫通して植設されている場合は、表皮基材層により成形性や耐久性を高めることができる。また、表皮基材層により第1非通気層が支持されるため、パイル糸を植設し易い。
また、前記パイル糸が、前記吸音層の裏面側にU字状に突出している場合は、パイル糸のU字状の突出部に第2非通気層を構成する材料が絡み易くなるため、パイル糸を第2非通気層により強固に固定することができる。
本実施形態1.に係るカーペットは、以下に述べる第1非通気層、吸音層及び第2非通気層を備える。このカーペットは、例えば、後述する表皮基材層を更に備えることができる。
本実施形態2.に係るカーペットの製造方法は、上記実施形態1.のカーペットの製造方法であって、前記第1非通気層及び前記吸音層を積層して、該吸音層側から該吸音層及び該第1非通気層に貫通して前記パイル糸を植設する第1工程と、前記パイル糸の植設された前記吸音層の裏面側に前記第2非通気層を積層する第2工程と、を備えることを特徴とする。
本実施例に係るカーペット1は、図1に示すように、表皮基材層2と、表皮層3(本発明に係る「第1非通気層」として例示する。)と、吸音層4と、バッキング材層5(本発明に係る「第2非通気層」として例示する。)と、を積層してなると共に、表皮基材層2、表皮層3及び吸音層4にパイル糸6が貫通されて植設されている。
次に、上記カーペット1の製造方法について説明する。
図2に示すように、不織布8をニードルパンチ9によりシート状にして吸音層4を得る(図2(A))。次に、表皮基材層2と、表皮層3と、吸音層4とを順に積層して、タフト機により吸音層4側からパイル糸6を全層4,3,2に貫通させて植設し、表皮基材層2側にパイルを形成する(図2(B))。その際、パイル糸6の反表皮側の先端部は、吸音層4に密着されずに僅かに浮いた状態とされ、U字状に突出する突出部7(図1参照)とされる。次いで、吸音層4の裏側にTダイラミネートによりバッキング材層5を形成する(図2(C))。その際、バッキング材はパイル糸6の突出部7に絡んでこれを抜けないように固定する。これにより、カーペット1が得られる。
図1に示すように、車室内の音はカーペット1の表面で受ける。その音は、パイル糸6を伝わって表皮層3を通過して吸音層4に達する。吸音層4に入った音は、非通気性の表皮層3及びバッキング材層5で反射されて吸音層4に留まる。そして、不織布からなる吸音層4により音は吸音されて減衰する。
一方、車室外からの音はカーペット1の裏面で受ける。その音は、バッキング材層5により反射される。
本実施例によれば、パイル糸6が表皮基材層2、表皮層3及び吸音層4を貫通しており、吸音層4の表裏側に非通気性の表皮層3及びバッキング材層7が積層されているので、車室内の音はパイル糸6を伝わって吸音層4に達して吸収され、その吸音層4に吸収された音の大部分は吸音層4に留まって減衰される。従って、吸音性を高めることができる。また、従来のように、パイル糸を植設した表皮層に吸音層を接着するものや非通気層に孔あけ処理を施すものに比べて、製造工程を削減することができ、生産性を高めることができる。また、表皮基材層2により成形性や耐久性を高めることができる。さらに、パイル糸6を植設する際に、表皮基材層2で表皮層3が支持されるため、パイル糸6を植設し易い。
また、表皮基材層2を非通気もしくは極めて非通気に近い状態にしたものとしてもよい。
図1に示すカーペット1において、表皮基材層2をスパンボンド不織布製で目付100g/m2とし、表皮層3を低密度PE製で目付30g/m2とし、吸音層4をニードルパンチ不織布製で目付300g/m2とし、バッキング材層5を低密度PE製で目付400g/m2とし、パイル糸6を原材料着色されたポリアミド製で目付420g/m2として、合計で1250g/m2とした。
図6に示すカーペット108において、表皮基材層110をスパンボンド不織布製で目付100g/m2とし、表皮ラテックス層111をラテックス製で目付50g/m2とし、PEパウダー層112を200g/m2とし、吸音不織布層113をニードルパンチ不織布製で目付300g/m2とし、バッキング材層114を低密度PE製で目付250g/m2とし、パイル糸109を原材料着色されたポリアミド製で目付350g/m2として、合計で1250g/m2とした。
Claims (5)
- 第1非通気層と、該第1非通気層の裏面側に設けられる吸音層と、該吸音層の裏面側に設けられる第2非通気層と、を備え、
前記第1非通気層及び前記吸音層に貫通し且つ前記第2非通気層に貫通せずにパイル糸を植設してなり、
前記吸音層は、前記第1非通気層の厚さより大きな厚さを有し、
前記吸音層を構成する不織布の繊維の繊度は、前記吸音層の厚みを維持するために2.2〜17デシテックスであることを特徴とするカーペット。 - 前記第1非通気層の表面側に設けられる表皮基材層を更に備え、前記パイル糸は、該表皮基材層、前記第1非通気層及び前記吸音層に貫通し且つ前記第2非通気層に貫通せずに植設されている請求項1記載のカーペット。
- 前記第1非通気層は、前記表皮基材層と前記吸音層とを接着する接着フィルムである請求項2記載のカーペット。
- 前記パイル糸は、前記吸音層の裏面側にU字状に突出している請求項1乃至3のいずれか一項に記載のカーペット。
- 請求項1乃至4のいずれか一項に記載のカーペットの製造方法であって、
前記第1非通気層及び前記吸音層を積層して、該吸音層側から該吸音層及び該第1非通気層に貫通して前記パイル糸を植設する第1工程と、
前記パイル糸の植設された前記吸音層の裏面側に前記第2非通気層を積層する第2工程と、を備えることを特徴とするカーペットの製造方法。
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JP2008149883A JP5266894B2 (ja) | 2008-06-06 | 2008-06-06 | カーペット及びその製造方法 |
US12/408,124 US8574700B2 (en) | 2008-06-06 | 2009-03-20 | Carpet and method of manufacture therefor |
CN200910140475XA CN101596062B (zh) | 2008-06-06 | 2009-05-15 | 地毯及其制造方法 |
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2008
- 2008-06-06 JP JP2008149883A patent/JP5266894B2/ja not_active Expired - Fee Related
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2009
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US8574700B2 (en) | 2013-11-05 |
JP2009291500A (ja) | 2009-12-17 |
CN101596062A (zh) | 2009-12-09 |
CN101596062B (zh) | 2012-06-13 |
US20090304982A1 (en) | 2009-12-10 |
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