JP3564973B2 - Carpet material - Google Patents

Description

【００７７】
【発明の効果】
本発明は以上説明したように、構成されるのであるから、本発明のカーペット材は、低周波域での遮音性能を効果的に向上させる効果を奏する。
【図面の簡単な説明】
【図１】本発明の一実施例のカーペット材の模式図である。
【図２】動的粘弾性試験の測定結果を示すグラフである。
【図３】機械的揉み解し処理による効果を示すグラフである。
【図４】本発明の一実施例のカーペット材の模式図である。
【図５】本発明の他の実施例のカーペット材の模式図である。
【図６】遮音性能測定方法を示す模式図である。
【符号の説明】
１ パイル部
２ 基布部
３ バッキング部
４ パイル部
５ 基布部
６ ニードルパンチ処理
７ バッキング部
８ パイル部
９ 基布一体バッキング部
１０ 測定側マイク
１１ 測定側残響室
１２ カーペット材
１３ インシュレータ材
１４ 鉄板
１５ 発音側残響室
１６ 発音側マイク
１７ スピーカ
１８ エアーシール[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a tufted carpet material having improved sound absorption and sound insulation performance, and a tufted carpet for an automobile using the carpet material.
[0002]
[Prior art]
Conventional carpet materials have, for example, a patterned pile portion on the surface of a non-woven fabric, such as a cord or a Deloitte tone, and a lower portion of the impregnated portion impregnated with latex for fixing the pile portion. (Japanese Patent Application Laid-Open Nos. 52-53980 and 61-132667). In addition, as a carpet material for automobiles, in addition to the above, a thermoplastic resin sheet such as a polypropylene or polyamide sheet or an ethylene-vinyl acetate copolymer (EVA) impregnated with an inorganic substance such as calcium carbonate below the latex portion. (Japanese Patent Application Laid-Open Nos. Sho 59-140175, 57-205251, and 59-204982).
[0003]
[Problems to be solved by the invention]
However, the performance required of the conventional carpet material is mainly the provision of surface design and the durability as a carpet material, and there has been no demand for sound vibration performance such as sound absorption performance and sound insulation performance. However, it has recently been found that it is important to pay particular attention to carpet materials for automobiles as a means for improving the sound vibration performance of vehicles.
The present invention has been made in view of such circumstances, and in order to improve the sound vibration performance of a carpet material, the entire carpet material is formed of a fibrous body, and in particular, a carpet material having improved sound vibration performance in a low frequency region. The purpose is to provide.
[0004]
[Means for Solving the Problems]
The above object is a tufted carpet material comprising a pile portion on the skin side, a base fabric portion supporting the pile portion, and a backing portion located on the back surface of the base fabric portion, wherein the backing portion is formed of a fiber aggregate. The backing portion has a surface density of 100 to 1000 g / m2. ² , Having a thickness of 0.5 to 6 mm and a fiber aggregate having a diameter of 10 to 30 μm, and a non-woven fabric constituting the backing portion having an air permeability of 0.01 kg / cm 2. ² Under the air pressure of 10 to 1000 cc / min, and the storage elastic modulus log E ′ (JIS K 7198 (Dynamics by non-resonant forced vibration method of plastic) in the dynamic viscoelasticity test of the nonwoven fabric constituting the backing portion. Characterized by the fact that the value of the above-mentioned test method for the temperature dependence of the dynamic viscosity is in the range of 5 to 10 Pa in the measurement temperature range of 0 to 50 ° C., which is achieved by providing the tufted carpet material. Is done.
[0005]
That is, the present invention relates to a carpet material provided with sound-absorbing and sound-insulating properties, such as sound absorption and sound insulation, which are not normally required for a carpet material, in a tufted carpet material for home use, automobile use, and the like, and constitutes a carpet material. It is characterized in that all parts are composed of fiber aggregates.
[0006]
As shown in FIG. 1, the carpet material of the present invention is formed with a configuration in which a pile portion 1 on the skin side, a base fabric portion 2 supporting the pile portion, and a backing portion 3 on the back surface of the base fabric portion 2. I have. The pile portion is a layer for imparting a design property, and has a pattern such as a chord tone or a diroa tone. A base fabric portion exists to support the bristle portion of the pile portion. Therefore, these two layers are inseparable from each other, and the base cloth portion exists to form the design of the skin portion of the carpet material.
[0007]
Further, the lower backing portion is a portion mainly configured in a carpet material for a vehicle, and is often installed in order to improve sound vibration performance. This backing part may be called a mass back part. In addition, since there is a case where the equivalent of the mass back portion is further laminated on the backing portion, there is no intentional limitation here.
[0008]
The present invention is characterized in that in the tufted carpet, the backing portion is a fibrous body. By using a fibrous body, the backing part becomes very soft under a certain amount compared to conventional thermoplastic resin sheets (PE, EVA, etc.), and in proportion to the degree of softness, sound insulation at low frequency positions It has been found that performance is improved.
[0009]
Although the pile portion and the base fabric portion are integrated, the backing layer of the fibrous body may be integrally formed, or may be separately formed as separate bodies and then integrated. This is because both backing layers are sufficiently soft as compared with the conventional material, and are effective in improving the sound insulation performance in a low frequency range.
[0010]
The pile portion is made of, for example, nylon fiber, polyester fiber, polypropylene fiber, or a mixed fiber thereof. Preferably, the pile portion is made of a fiber mainly composed of a nylon fiber or a polyester fiber.
[0011]
The base fabric portion is made of, for example, a polyester fiber nonwoven fabric, a polypropylene fiber nonwoven fabric, or the like. Preferably, the base fabric portion is made of a polyester fiber nonwoven fabric.
[0012]
The nonwoven fabric forming the backing portion is made of, for example, polyester fiber, polypropylene fiber, or the like, and is particularly preferably made of polyester fiber. Polyester fiber is a very common fiber and has a feature of high degree of freedom in production, because the backing portion made of polyester fiber can be softened most efficiently. Furthermore, since polyester is a thermoplastic resin, it can be easily recycled and reused, and is an environmentally friendly substance.
[0013]
The polyester fibers may include recycled polyester fibers. Recycled polyester fibers, whose mechanical properties are not so different from virgin polyester, are also very widely distributed, and it is important to actively use them from the viewpoint of environmental aspects and the like.
The nonwoven fabric constituting the backing portion has an area density of 100 to 1000 g / m. ² And a polyester fiber having a thickness of 0.5 to 6 mm and a diameter of 10 to 30 μm. More preferably, the nonwoven fabric constituting the backing portion has an areal density of 150 to 600 g / m2. ² And a polyester fiber having a thickness of 1 to 4 mm and a diameter of 10 to 20 μm.
[0014]
Area density is 100g / m ² With a nonwoven fabric having a thickness of less than 1000 g / m 2, no superiority in sound insulation performance is obtained even when the backing portion is formed. ² This is because, in the case of exceeding, the backing layer becomes harder than the conventional product, and the superiority of the sound insulation performance in a low frequency range is lost. If the thickness of the backing layer is less than 0.5 mm, the durability as a carpet material is poor, and it cannot withstand long-time use. If it is more than 6 mm, the carpet material itself becomes too thick, resulting in poor practicality. Further, the thinner the polyester fiber constituting the backing portion is, the more effective the sound and vibration performance is. However, since the fiber becomes expensive and the rigidity of the fiber itself is insufficient, the fiber of less than 10 μm is practically used. Not suitable. Further, the fibers having a diameter of more than 30 μm are too thick, so that the backing layer becomes hard, and there is a possibility that the water cannot be shielded when water is spilled.
[0015]
The nonwoven fabric constituting the backing portion is made of a polyester staple fiber, a core composed of, for example, a high melting point copolyester (for example, having a melting point of 230 to 250 ° C) and a sheath component composed of a low melting point copolyester (for example, having a melting point of 110 to 180 ° C). It is preferable that the binder fiber is composed of a mixture of binder fibers having a sheath-type conjugate structure, and the binder fibers be blended in an amount of 20 to 80% by weight. Here, the binder fiber refers to a fiber that binds polyester staple fibers or conjugate fibers constituting the nonwoven fabric.
[0016]
This is because the blending of the binder fiber makes it possible to heat-mold the carpet material, thereby increasing the degree of freedom in molding. In addition, in the case of carpet materials for automobiles, it is necessary to mold the carpet material according to the shape of the floor of the automobile, so that the blending of this binder fiber is necessary.
[0017]
If the blending amount of the binder fiber is small, molding is not actually possible, and moldability cannot be imparted to the carpet material. Therefore, blending of 20% by weight or more is required. On the other hand, when the content of the binder fiber exceeds 80% by weight, the backing portion is hardened, and there is a possibility that the sound insulation performance in a low peripheral region is adversely affected.
[0018]
The low-melting copolyester is, for example, a polyethylene terephthalate composed of ethylene glycol and terephthalic acid, a polyester composed of ethylene glycol and ortho-phthalic acid, or a polyester composed of a mixture of a polyester composed of ethylene glycol and meta-phthalic acid. The melting point means 110 to 180 ° C.
[0019]
The core component constituting the core-sheath conjugate structure is composed of, for example, a high-melting polyester. Here, the high melting point polyester means a polyester having a melting point of 230 to 250 ° C.
[0020]
The polyester staple fiber constituting the nonwoven fabric constituting the backing portion is a regular fiber or conjugate fiber having a normal round section fiber, or a recycled polyester regular fiber, or a regular fiber or a conjugate fiber having a hollow section hollow fiber, or a sectional shape. Is preferably a modified cross-section fiber having a non-circular shape, a split fiber split in a direction perpendicular to the cross-sectional direction, or a mixture of at least two kinds of these fibers.
[0021]
Compared to conventional materials, the backing part is sufficiently soft even when the backing part is composed of round fibers that are ordinary fibers, but in order to further improve sound insulation performance, use of fibers with irregular cross-section other than fibers with round cross-section Is very effective. When the cross-sectional area of a single fiber is defined as S and the converted diameter R is defined as in Formula 1, the modified cross-sectional fiber is a fiber having a cross-sectional shape represented by Formula 2 where L is the outer peripheral length of the cross-sectional area. Say.
(Equation 1)
R = 2√ (S / π) (Equation 1)
1.2 πR <L <5πR (Equation 2)
[0022]
The use of the modified cross-section fiber has the effect of softening the backing portion and, at the same time, securing a surface area per unit volume, and thus has the effect of imparting sound absorbing performance to the backing portion. The modified cross-section fiber includes a flat cross-section fiber, a Y-section cross-section fiber, a W-section cross-section fiber, an elliptic fiber, an ultra-flat cross-section fiber, etc., all of which are effective for achieving the above object, but are not particularly limited. Absent.
[0023]
The split fibers split in the direction perpendicular to the cross-sectional direction are configured as bundles of ultra-fine fibers. Usually, the split fibers are divided into six sections divided into a 60 ° fan-shaped cross section from the center of the cross section. There are fibers and eight-split fibers which are divided into 45-degree sectors from the center of the cross section. All of them are effective in reducing the storage elastic modulus of the backing portion and improving the surface area.
[0024]
Since the surface area and the like of the split fibers are improved by splitting, the number of splits is not limited, but a split fiber having a fan shape in the range of 30 to 60 ° is generally used and is economically suitable.
[0025]
Hollow fibers are also effective because they have the effect of increasing the surface area under the same surface density.
[0026]
Regular fibers are characterized by being mechanically crimped and having a strong rebound in the plane direction, and conjugate fibers are chemically crimped and have a feature that the backing portion can be bulky. Both of them can be used to adjust the softness of the backing portion and are effective.
[0027]
A mixture of these fibers is also very effective in adjusting the softness of the backing portion. Although there are many combinations of these fiber types, they are not particularly limited because they are effective for the above purpose.
[0028]
The melting point of the low-melting point copolyester blended in the nonwoven fabric constituting the backing portion is preferably 110 to 180 ° C. This temperature range is a range necessary for imparting moldability to the backing material. If the temperature is lower than 110 ° C., for example, when the carpet material is used in a high-temperature atmosphere, it may be difficult to maintain the shape of the carpet. On the other hand, when the temperature exceeds 180 ° C., the allowable range of the heating conditions is narrowed, and the degree of freedom in molding is reduced. Further, there is a problem that the forming conditions are strict and the versatility is reduced.
[0029]
The air permeability of the nonwoven fabric constituting the backing part is 0.01 kg / cm ² Under an air pressure of 10 to 1000 cc / min. The ventilation amount of the backing portion affects the sound insulation performance in a high frequency range, and the sound insulation performance in a high frequency range is ensured when the ventilation resistance is more than a certain level. The high frequency here mainly means a range of 1 kHz or more. The ventilation resistance is 0.01 kg / cm ² If the air flow rate is in the range of 10 to 1000 cc / min, the sound insulation performance in a high frequency range can be secured. This means that due to such a degree of airflow resistance, even if there is a certain amount of airflow, it becomes an acoustically completely shield. In order to realize a situation of 10 cc / min or less with a fibrous backing material, the areal density is 1000 g / m. ² As described above, the backing material is hardened, and the sound insulation performance in a low frequency range is deteriorated. If the air flow rate exceeds 1000 cc / min, an acoustic partition cannot be formed, and the sound insulation performance in a high frequency range cannot be ensured. This range of the amount of ventilation substantially coincides with the range of 5% or less of the opening ratio of the film having no ventilation.
[0030]
It is preferable that the value of the storage elastic modulus log E ′ in the dynamic viscoelasticity test of the nonwoven fabric constituting the backing portion is in the range of 5 to 10 Pa in the measurement temperature range of 0 to 50 ° C.
[0031]
The softness of the backing part is quantitatively represented by the value of storage elastic modulus in a dynamic viscoelasticity test. The guideline of the softness of the backing portion is also determined by the value of the storage elastic modulus. It is desirable that the value of the storage elastic modulus log E ′ be as small as possible in the measurement temperature range of 0 to 50 ° C. for improving the low-frequency sound insulation performance. However, the sound insulation performance in the low frequency range means the region of the primary resonance of the double-walled sound insulation structure formed between the backing portion and the outer wall. In this region, the sound insulation performance is usually based on mass law. (Figure 2). However, it has been found for the first time that the drop in this region can be made as close as possible to the mass law by the value of the storage elasticity log E ', and that the superior sound insulation performance of a normal double-wall sound insulation structure can be ensured in a high frequency region.
[0032]
Here, the mass law refers to the backing M ₁ And outer wall M ₂ Means that the transmission loss and the frequency are proportional to the sound insulation structure that is closely connected without passing through the insulator. Backing M ₁ And outer wall M ₂ In the conventional double-wall structure in which an insulator is provided between the two walls, the sound insulation performance is worse than the mass law in the frequency region of 200 to 500 Hz due to the primary resonance between the double walls, as shown in FIG. In the present invention, it is possible to remarkably suppress the deterioration of the resonance by adopting the above configuration. Further, in the carpet material of the present invention, as is clear from FIG. 2, in the high frequency region, the overall sound insulation performance is higher than the mass law. In addition, when the double wall structure and the mass law are described side by side as shown in FIG. 2, it is assumed that the double wall structure and the mass law structure have the same weight (constant weight).
[0033]
At this time, in the temperature range of 0 to 50 ° C., the backing material having a pressure of less than 5 Pa is too soft and cannot be formed into a sheet when the backing material is used, which is inconvenient. In the case where the temperature is more than 10 Pa in the temperature range of 0 to 50 ° C., softness sufficient to improve the sound insulation performance in the low frequency region cannot be obtained, and as in the normal double state, the mass law in the low frequency region is large. She was drained and was unsuitable. Specifically, mechanically loosening the backing portion and softening the nonwoven fabric backing is also very effective for improving low-frequency sound insulation performance. The upper part in FIG. 3 of the value of the storage elastic modulus as a result of the dynamic viscoelasticity test in FIG. 3 is the invention backing material before mechanical kneading and breaking, and the lower part is the invention backing material after treatment. Thus, the mechanical kneading treatment is very effective in reducing the storage elastic modulus.
[0034]
It is very effective to use the tufted carpet material of the present invention as an automobile floor carpet. The demand for quietness of automobiles is increasing year by year. That is, when the floor carpet is formed by integrating the tufted carpet material with the insulator layer, the height is higher in the entire frequency range from the low frequency range to the high frequency range as compared with the floor carpet for automobiles using the conventional carpet material. This is because a floor carpet having sound insulation and sound absorption performance can be obtained.
[0035]
That is, the present invention also provides an automobile floor carpet comprising the carpet material of the present invention and an insulator layer.
[0036]
The present invention also provides a method for manufacturing the floor carpet for an automobile, wherein the manufacturing method comprises laminating an insulator layer made of a fiber aggregate and the tufted carpet material of the present invention, and forming the carpet material. By heating at a temperature equal to or higher than the melting point of the low-melting copolyester blended in the backing portion, the backing portion of the carpet material is fused to the insulator layer, and laminated to form a floor kakipet for automobiles. Features. Since the low melting point means 110 to 180 ° C. as described above, the insulator layer and the carpet material are heated at the temperature or higher. Here, the insulator layer is made of, for example, a fiber aggregate such as polyester fiber or felt or urethane.
[0037]
As described above, when manufacturing a floor carpet for an automobile from the carpet material of the present invention, an insulator layer made of a fiber aggregate and the carpet material are integrated with each other, and a low-melting copolyester blended in the backing portion is used. By heating at a temperature equal to or higher than the melting point, a backing portion or a mass back layer is fused to the insulator layer, and a method of obtaining an automobile floor carpet by lamination and integration can be used. Since this method is simple and excellent in terms of the process, it is highly versatile and economical.
[0038]
It is effective to integrate the backing part with the base cloth part of the carpet material. Usually, the fibrous material of the pile portion is sewn to the base fabric portion to form a carpet skin.However, by changing the backing portion from a conventional resin to a non-woven fabric, it is possible to use the same material as the base fabric portion. Lamination and integration of the base fabric and the backing, which were possible, are now possible. Accordingly, the pile fibers are sewn on the backing integrated with the base cloth having a surface density obtained by adding the respective surface densities of the base cloth portion and the backing portion (FIG. 5), or the normal pile portion and the base cloth portion are integrated. It is also possible to laminate and integrate the backing portion on the outer skin by the needle punch method, which is sufficient to achieve the object of the present invention. In addition, it is naturally possible to use an adhesive or to laminate and integrate with a binder fiber blended in the backing portion or the base fabric portion, which is sufficient for the purpose of the present invention.
[0039]
The carpet material of the present invention has all the requirements originally required as a tufted carpet material, and can be a carpet material having excellent sound insulation performance and sound absorption performance in a wide range from a low frequency region to a high frequency region. became.
[0040]
【Example】
Examples of the present invention will be described below.
Example 1
On a back surface of a base portion made of a pile portion mainly composed of nylon fibers and a polyester fiber non-woven fabric supporting the pile portion, 70% by weight of split fibers having a fiber diameter of about 15 μm, and polyester binder fibers having a fiber diameter of about 15 μm In a three-layer integrated carpet material having a backing portion blended with a type in which the melting point of the copolyester of the sheath is 110 ° C. and the melting point of the core copolyester is 240 ° C., the areal density of the backing is 400 g / m ² , Thickness 3mm, 0.01kg / cm ² Is 450 cc / min under air pressure, and the average value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 8.5 Pa in the measurement temperature range of 0 to 50 ° C. The carpet material (1) was produced using the thing.
In this example, the three-layer integration of the pile portion, the base fabric portion, and the backing portion is performed by the following method, that is, the pile portion is inserted into the base fabric portion, and then the heated backing portion is thermally fused to the base fabric portion. Was. The binder component in the backing portion fused to the base fabric portion.
[0041]
Example 2
On a back surface of a pile portion mainly composed of polyester fibers and a backing portion supporting the pile portion, 70% by weight of a split fiber having a fiber diameter of about 15 μm, and a sheath of a polyester-based binder fiber having a fiber diameter of about 15 μm. In a three-layered carpet material having a backing portion in which 30% by weight of a polyester having a melting point of 110 ° C. and a polyester having a melting point of 240 ° C. in the core portion has a surface density of 400 g / m. ² , Thickness 3mm, 0.01kg / cm ² Is 450 cc / min under air pressure, and the average value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 8.5 Pa in the measurement temperature range of 0 to 50 ° C. The carpet material (2) was produced using the thing.
[0042]
Example 3
800g / m area density of backing part ² , Thickness 5mm, 0.01kg / cm ² Is 50 cc / min under air pressure, and the value of storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 9.5 Pa on average in the range of the measurement temperature range of 0 to 50 ° C. A carpet material (3) was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0043]
Example 4
Backing part area density 200g / m ² , Thickness 2mm, 0.01kg / cm ² Is 750 cc / min under air pressure, and the value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 7.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material (4) was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0044]
Example 5
A split fiber having a fiber diameter of about 15 μm other than the binder fiber constituting the backing part, having a thickness of 2 mm and 0.01 kg / cm 2 ² The air permeability under an air pressure of 420 cc / min and the value of storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material averaged 8.0 Pa in the measurement temperature range of 0 to 50 ° C. A carpet material (5) was produced in exactly the same manner as in Example 1 except for using the same.
[0045]
Example 6
A carpet material (6) was produced in exactly the same manner as in Example 1 except that the melting point of the copolyester of the binder fiber constituting the backing portion was set to 130 ° C.
[0046]
Example 7
A carpet material (7) was produced in exactly the same manner as in Example 1 except that the melting point of the copolyester of the binder fiber constituting the backing portion was 170 ° C.
[0047]
Example 8
A carpet material (8) was produced in exactly the same manner as in Example 1 except that the melting point of the copolyester of the binder fiber constituting the backing portion was set to 180 ° C.
[0048]
Example 9
The blending amount of the binder fiber constituting the backing portion was 20% by weight, the blending amount of the other split fibers was 80% by weight, and the value of the storage elastic modulus (log E ′) of the dynamic viscoelasticity test of the backing material was A carpet material (9) was produced in exactly the same manner as in Example 1 except that the average temperature was 8.2 Pa in the measurement temperature range of 0 to 50 ° C.
[0049]
Example 10
The blending amount of the binder fiber constituting the backing portion was 50% by weight, the blending amount of the other split fibers was 50% by weight, and the value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material was A carpet material (10) was produced in exactly the same manner as in Example 1, except that the measurement temperature range was 0 to 50 ° C and the average was 8.7 Pa.
[0050]
Example 11
The blending amount of the binder fiber constituting the backing portion was 80% by weight, the blending amount of the other split fibers was 20% by weight, and the value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material was A carpet material (11) was produced in exactly the same manner as in Example 1, except that the measurement temperature range was 0 to 50 ° C and the average was 8.8 Pa.
[0051]
Example 12
Fibers other than the binder fiber constituting the backing portion are made into regular fibers having a round cross section with a fiber diameter of about 10 μm, and are 0.01 kg / cm. ² Of 400 cc / min under air pressure, and the average value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material was 7.5 Pa in the measurement temperature range of 0 to 50 ° C. A carpet material (12) was produced in exactly the same manner as in Example 1.
[0052]
Example 13
Fibers other than the binder fiber constituting the backing portion are conjugate fibers having a round cross-section faithful having a fiber diameter of about 10 μm, and have a thickness of 8 mm and a weight of 0.01 kg / cm. ² With the exception that the air flow rate under air pressure was 410 cc / min and the value of the storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material was 8.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material (13) was produced in exactly the same manner as in Example 1.
[0053]
Example 14
Fibers other than the binder fiber constituting the backing part are Y-shaped cross-section fibers having a fiber diameter of about 15 μm, and are 0.01 kg / cm 2. ² Except that the air permeability under the air pressure was 420 cc / min, and the value of the storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material was 8.7 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material (14) was produced in exactly the same manner as in Example 1.
[0054]
Example 15
The fibers other than the binder fibers constituting the backing portion are made into flat cross-section fibers having a fiber diameter of about 15 μm, and are 0.01 kg / cm 2. ² Of 430 cc / min under the air pressure of, and the average value of the storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material was 8.2 Pa in the measurement temperature range of 0 to 50 ° C. A carpet material (15) was produced in exactly the same manner as in Example 1.
[0055]
Example 16
The fibers other than the binder fibers constituting the backing portion are made into elliptical cross-section fibers having a fiber diameter of about 15 μm, and are 0.01 kg / cm 2. ² Of 425 cc / min under the air pressure of, and the average value of the storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material was 8.4 Pa in the measurement temperature range of 0 to 50 ° C. A carpet material (16) was produced in exactly the same manner as in Example 1.
[0056]
Example 17
Fibers other than the binder fiber constituting the backing part are made of recycled polyester regular fiber having a fiber diameter of about 15 μm, and are 0.01 kg / cm 2. ² Of 425 cc / min under an air pressure, and the average value of the storage elastic modulus (log E ') in the dynamic viscoelasticity test of the backing material was 7.6 Pa in the measurement temperature range of 0 to 50 ° C. A carpet material (17) was produced in exactly the same manner as in Example 1.
[0057]
Example 18
By mechanically loosening the backing part and softening it very flexibly, the value of the storage elastic modulus (log E ') of the dynamic viscoelasticity test of the backing material is averaged in the measurement temperature range of 0 to 50 ° C. A carpet material (18) was produced in exactly the same manner as in Example 3, except that the pressure was set to 6.0 Pa.
[0058]
Example 19
By mechanically loosening the backing part and softening it very flexibly, the value of the storage elastic modulus (log E ') of the dynamic viscoelasticity test of the backing material is averaged in the measurement temperature range of 0 to 50 ° C. A carpet material (19) was produced in exactly the same manner as in Example 1 except that the pressure was set to 7.5 Pa.
[0059]
Example 20
By mechanically loosening the backing part and softening it very flexibly, the value of the storage elastic modulus (log E ') of the dynamic viscoelasticity test of the backing material is averaged in the measurement temperature range of 0 to 50 ° C. A carpet material (20) was produced in exactly the same manner as in Example 3 except that the pressure was set to 8.5 Pa.
[0060]
Example 21
The nonwoven fabric constituting the backing portion 7 is manufactured by a card layer type nonwoven fabric manufacturing apparatus, and the skin constituted by the pile portion 4 and the base fabric portion 5 is laminated and integrated by performing a needle punching process 6 in a downstream process to form a carpet material ( 21) was prepared (FIG. 4).
[0061]
Example 22
A nonwoven fabric forming an integrated backing material in which a backing portion and a base fabric portion are integrated is manufactured by a card layer type nonwoven fabric manufacturing apparatus, and thereafter, a pile portion 8 is formed by a pile portion processing step, and the integrated base fabric integrated backing is formed. A carpet material (22) having a portion 9 was prepared (FIG. 5).
[0062]
Example 23
Using the carpet material obtained in Example 1, a floor carpet for an automobile is manufactured. That is, the carpet material obtained in Example 1 and an insulator layer made of an aggregate of polyester fibers are laminated, and heated at a temperature of 160 ° C. (specify a temperature of 110 ° C. or more). The backing portion of the carpet member was fused and laminated and integrated to obtain an automobile floor carpet.
[0063]
Example 24
A carpet floor carpet is manufactured using the carpet material obtained in Example 2. That is, the carpet material obtained in the example was laminated with an insulator layer composed of an aggregate of polyester fibers, heated at a temperature of 160 ° C., and the backing portion of the carpet member was fused to the insulator layer to form a laminate. To give a car floor carpet.
[0064]
Comparative Example 1
100g / m area density of backing part ² , 0.01kg / cm ² And the storage elastic modulus (log E ′) of the dynamic viscoelasticity test of the backing material is 6.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0065]
Comparative Example 2
Backing area density of 1100g / m ² , 0.01kg / cm ² Is 5 cc / min under an air pressure, and the value of storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 11.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0066]
Comparative Example 3
The thickness of the backing part is 0.2mm, 0.01kg / cm ² Is 4 cc / min under air pressure, and the value of storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 10.5 Pa on average in the range of the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0067]
Comparative Example 4
Backing part thickness 11mm, 0.01kg / cm ² Is 500 cc / min under air pressure, and the value of storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material is 8.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1 except that a carpet material was used.
[0068]
Comparative Example 5
An attempt was made to form the backing portion by setting the blending amount of the binder fiber constituting the backing portion to 10% by weight, but the fibrous bodies were not united and a fiber aggregate functioning as the backing portion could not be obtained.
[0069]
Comparative Example 6
The blending amount of the binder fiber constituting the backing portion was set to 90% by weight, and the value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material was 10 on average in the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1 except that the pressure was set to 4 Pa.
[0070]
Comparative Example 7
An attempt was made to form the backing portion in the same manner as in Example 1 except that the fibers other than the binder fiber constituting the backing portion were solid regular fibers having a round cross section having a fiber diameter of about 5 μm, but the constituent fibers were too thin to be bundled. Thus, a fiber aggregate functioning as a backing portion could not be obtained.
[0071]
Comparative Example 8
Fibers other than the binder fiber constituting the backing part are solid regular fibers having a circular cross section of about 40 μm in diameter and 0.01 kg / cm ² With the exception that the air permeability under the air pressure of 1100 cc / min and the value of the storage elastic modulus (log E ′) in the dynamic viscoelasticity test of the backing material were 9.0 Pa on average in the measurement temperature range of 0 to 50 ° C. A carpet material was produced in exactly the same manner as in Example 1.
[0072]
(Test example)
The following experiments were performed on the carpet materials obtained in Examples 1 to 24 and Comparative Examples 1 to 4, 6, and 8.
[0073]
Test example (transmission loss experiment)
For the carpet material obtained by the method of each of the above Examples and Comparative Examples, a sound transmission loss measurement was performed using a reverberation room according to JIS A1416. In the measurement, the backing portion side of the carpet material (12) obtained by the method of the embodiment or the like was overlapped with the insulator material (13) made of a polyester fiber sound-absorbing material. (14) A sample was set in such a manner that 1 mm was set, an insulator material was stuck on the iron surface, and a double-walled sound insulation structure was formed by the iron plate and the backing portion (FIG. 6).
[0074]
The test results are shown in Table 1. The low-frequency-side sound insulation performance at this time means that the PE sheet of the conventional material is used only for the backing part of the carpet material, and that the same surface density is compared. It is the result of averaging the difference between (dB) and the measured sound pressure (dB) when using a PE sheet from 50 to 500 Hz. The measured sound pressure when a PE sheet is used is a constant 20.0 dB (average value of 50 to 500 Hz). When the value of the sound pressure difference is positive, the configuration using the carpet material shown in the embodiment has higher sound insulation performance.
According to these test results, it was confirmed from Table 1 that the carpet material prepared in the example has improved sound insulation performance in a low frequency range (50 to 500 Hz) as compared with the configuration using the conventional material. Further, in the frequency range of 500 Hz or more, although there is no significant difference between the conventional example, the result of the embodiment is slightly better in sound insulation performance.
[0075]
In addition, the carpet material according to the comparative example prepared according to the conventionally known specifications could not be obtained because a satisfactory value could not be obtained with respect to the sound insulation performance in a low frequency range, or a structural problem as a carpet material was raised.
[0076]
[Table 1]

[0077]
【The invention's effect】
Since the present invention is configured as described above, the carpet material of the present invention has an effect of effectively improving sound insulation performance in a low frequency range.
[Brief description of the drawings]
FIG. 1 is a schematic view of a carpet material according to one embodiment of the present invention.
FIG. 2 is a graph showing measurement results of a dynamic viscoelasticity test.
FIG. 3 is a graph showing an effect of a mechanical kneading process.
FIG. 4 is a schematic view of a carpet material according to one embodiment of the present invention.
FIG. 5 is a schematic view of a carpet material according to another embodiment of the present invention.
FIG. 6 is a schematic diagram showing a method of measuring sound insulation performance.
[Explanation of symbols]
1 pile section
2 Base cloth
3 Backing part
4 pile section
5 Base fabric
6 Needle punching
7 Backing part
8 pile section
9 Base fabric integrated backing
10 Measuring microphone
11 Measurement side reverberation room
12 Carpet material
13 Insulator material
14 Iron plate
15 Reverberation room on the sounding side
16 Sounding microphone
17 Speaker
18 air seal

Claims (7)

A tufted carpet comprising a pile portion, a base fabric portion supporting the pile portion, and a backing portion located on the back surface of the base fabric portion, wherein the backing portion is made of a nonwoven fabric made of a fiber aggregate, and the backing portion is made of a nonwoven fabric. Is composed of a fiber aggregate having an areal density of 100 to 1000 g / m ² , a thickness of 0.5 to 6 mm, and a diameter of 10 to 30 μm, and the nonwoven fabric of the backing portion has an air permeability of 0. Under an air pressure of 0.01 kg / cm ² , the storage modulus log E ′ in the dynamic viscoelasticity test of the nonwoven fabric constituting the backing portion is in the range of 10 to 1000 cc / min. The tufted carpet material, wherein the temperature is in a range of 5 to 10 Pa at a temperature of ° C. The nonwoven fabric constituting the backing portion is a mixture of a polyester staple fiber and a binder fiber having a core-in-sheath conjugate structure in which the sheath component is made of a low-melting copolyester, and the binder fiber contains 20 to 50% in the backing portion. The tufted carpet material according to claim 1, which is blended at 80% by weight. The polyester staple fiber forming the nonwoven fabric constituting the backing portion is a regular fiber or conjugate fiber having a round cross section fiber, a regular fiber or a conjugate fiber having a round cross section hollow fiber, and the circumference of the fiber has a reduced diameter of 1.2π or more. 3. The fiber according to claim 1, wherein the fiber is a modified cross-section fiber having a shape of 5π times, a split fiber divided in a direction perpendicular to a cross-section direction, or a mixture of at least two kinds of these fibers. 4. Tufted carpet material. The tufted carpet material according to claim 3, wherein the low-melting copolyester blended in the nonwoven fabric constituting the backing portion has a melting point of 110 to 180 ° C. An automobile floor carpet comprising the tufted carpet material according to any one of claims 1 to 4 and an insulator layer. An insulator layer made of a fiber aggregate and the tufted carpet material according to claim 1 are laminated, and heated at a temperature equal to or higher than the melting point of the low-melting copolyester blended in the backing portion of the carpet material. A method of manufacturing a floor carpet for an automobile, comprising: fusing a backing portion of the carpet material to the carpet material; A tufted carpet material used as a floor carpet for automobiles, the carpet comprising a pile portion on the skin side, a base fabric portion supporting the pile portion, and a backing portion located on the back surface of the base fabric portion, The backing portion is made of a nonwoven fabric made of polyester, and the entire carpet material is made of a nonwoven fabric made of a polyester fiber aggregate. The nonwoven fabric forming the backing portion has an areal density of 100 to 1000 g / m ² and a thickness of 0.1 g / m ² . 5 to 6 mm, the air permeability under the air pressure of 0.01 kg / cm ² is in the range of 10 to 1000 cc / min, and the value of the storage elastic modulus log E ′ in the dynamic viscoelasticity test is within the measurement temperature range of 0 to 0. At 50 ° C., the non-woven fabric constituting the backing portion is in the range of 5 to 10 Pa, and the non-woven fabric is a polyester staple having a diameter of 10 to 30 μm. It is composed of a mixture of a fiber and a binder fiber having a core-sheath type conjugate structure in which the sheath component is made of a low-melting point copolyester. The binder fiber is blended in an amount of 20 to 80% by weight. ~ 180 ° C, polyester staple fiber is a regular fiber or conjugate fiber of round section fiber, or regular fiber or conjugate fiber of round section hollow fiber, or the circumference of the fiber is 1.2π of diameter The tufted carpet material, wherein the tufted carpet material is a modified cross-section fiber having a shape of 5π times, a split fiber split in a direction perpendicular to a cross-section direction, or a mixture of these fibers.

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