JP3610668B2 - Car trunk floor carpet - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a trunk floor carpet that is installed to prevent external vibration and / or noise from entering and protect luggage placed in a trunk.
[0002]
[Prior art]
A conventional car trunk floor carpet has a structure in which a thin non-woven fabric is bonded to the surface of felt or the like. A spare tire is installed in the lower part of the trunk and covered with a hard board, and a trunk floor carpet is laid on the spare tire. There are many things.
[0003]
[Problems to be solved by the invention]
By the way, the trunk floor carpet for automobiles is mainly required to have the following three performances. (1) Good sound insulation, such as road noise reduction, (2) Thermal insulation that does not adversely affect the luggage in the trunk through the steel plate, (3) Rigidity that does not deform with heavy objects placed in the trunk .
[0004]
However, when felt is used, sound insulation and heat insulation are improved by increasing the thickness. In addition, with the conventional structure, there is a problem that a hard board is laid when assembling and a carpet is further laid on the hard board, and the same trouble is taken when a spare tire is taken out.
[0005]
The present invention has been made paying attention to the conventional problems as described above, and an object of the present invention is a trunk that has good sound insulation performance and heat insulation performance, and can eliminate the spare tire cover to improve the convenience of the operator. To provide carpet.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, according to the first aspect of the present invention, in the floor carpet installed on the trunk floor of an automobile, the floor carpet is made of a nonwoven fabric made of short thermoplastic synthetic fibers and is hard. It consists of a layer and a soft layer, and this soft layer exists in the form pinched | interposed between two hard layers, It was set as the structure used as a sound-insulation / heat-insulation structure and a weight support member. In the invention described in claim 2, the short fibers constituting one of the hard layers are colored before dyeing or spinning. In the invention of claim 3, the non-woven fabric includes at least two kinds of short fibers mainly including a high softening point polyester staple and a low softening point polyester staple having a softening point lower by at least 20 ° C. It was. In the invention according to claim 4, the maximum bending load of the hard layer is 2 kgf or more, and the ratio of the maximum bending load of the hard layer to the soft layer is 10: 1 or more. In the invention according to claim 5, the blend amount of the low softening point polyester staple contained in the hard layer is 40% or more. In the invention according to claim 6, the thickness of the laminated hard layer and soft layer is 10 to 30 mm.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention are described below.
[0008]
In a floor carpet installed on a trunk floor of an automobile where vibration and / or noise is incident, the floor carpet is composed of a nonwoven fabric made of short fibers of thermoplastic synthetic fibers, and is composed of a hard layer and a soft layer, The layer is present in a form sandwiched between two hard layers, and is a sound-insulating / heat-insulating structure and a weight supporting member capable of supporting a heavy object placed in the trunk.
[0009]
Sound insulation performance can be realized by having a sparse part such as an air layer between homogeneous materials, but similar performance can be realized by sandwiching a soft layer between hard layers. Similarly, the heat shielding performance is excellent from the viewpoint of heat conduction due to the presence of a layer similar to the air layer in the middle rather than a homogeneous structure.
[0010]
In addition, by molding according to the shape of the panel surface of the automobile, it is possible to reduce the floor carpet displacement and the dent due to the presence of a gap with the panel surface.
[0011]
In the case of a nonwoven fabric, it is composed of entangled fibers and binder fibers that are further entangled with the fibers, and the hardness can be easily changed to some extent by changing the fiber diameter, the amount of binder fibers, etc. Is desirable. Of course, the above configuration can also be realized with felt or the like, but changing the hardness is not preferable because it leads to an increase in cost.
[0012]
Further, the surface is preferably a colored layer for use as an interior material. The hardness of the hard layer is preferably 2 kgf or more from the viewpoint of the support member, and the ratio of the hardness of the hard layer to the soft layer is preferably 10: 1 or more, and if the soft layer becomes harder than that, sound insulation It is not preferable in terms of performance. The thickness of the part is desirably 30 mm or less in terms of work, and is desirably 10 mm or more from the viewpoint of ensuring performance.
[0013]
Next, examples of the present invention will be described.
(Example 1)
(1) 30 denier of polyethylene terephthalate (hereinafter referred to as PET) fiber of 2 denier x 51 mm and 3 denier x 51 mm core-sheath conjugate type heat-sealing fiber (core component: core component) PET, sheath component: copolymer polyester having a melting point of 130 ° C.) A weight of 700 g / m obtained by carrying out needle punching conditions (needle punching needle degree, etc.) so that the maximum bending load is 2 kgf for a fiber assembly composed of 70% ^2. Needle punching conditions are appropriately selected from a molded non-woven fabric with a thickness of 15 mm, and a fiber assembly consisting of 90% PET fiber of 13 denier x 51 mm and 10% of conjugate fiber of 3 denier x 51 mm as a soft layer. 300 g / m ^{2 of} basis weight, 15 mm in thickness, and a molded nonwoven fabric with a maximum bending load of 0.1 kgf, and (3) as a lower hard layer A non-colored molded non-woven fabric having the same composition as 1 ▼ was laminated in the above order, heat-treated at 180 ° C., and then molded and compressed to 20 mm to obtain a sample.
(Example 2)
A sample was obtained in exactly the same manner as in Example 1 except that the final thickness was 10 mm.
(Example 3)
A sample was obtained in exactly the same manner as in Example 1 except that the final thickness was 30 mm.
(Example 4)
A sample was obtained in exactly the same manner as in Example 1 except that the heat-sealing component was 40% and PET was 60%.
[0014]
Next, a comparative example will be described.
(Comparative Example 1)
A sample was obtained in exactly the same manner as in Example 1, except that the soft layer was eliminated, the layer was homogeneous, and the basis weight was 1700 g / m ² .
(Comparative Example 2)
A sample was obtained in exactly the same manner as in Example 1, except that the maximum bending load of the fiber assembly forming the hard layer was adjusted to 1 kgf by adjusting the needle punch conditions.
(Comparative Example 3)
A sample was obtained in exactly the same manner as in Example 1 except that the hardness of the soft layer was increased and the hardness ratio was 5: 1.
(Comparative Example 4)
A sample was obtained in exactly the same manner as in Example 1 except that the final thickness was 5 mm.
(Comparative Example 5)
In Example 1, the molding was carried out in the same manner except that the heat fusion component was 30% and PET was 70%. However, the maximum bending rigidity of the hard layer was 1.6 kgf, and 2 kgf necessary as a spare tire cover was obtained. There wasn't.
FIG. 1 is a diagram collectively showing the configurations of the above-described examples and comparative examples.
[0015]
Moreover, the said Example and comparative example were evaluated with the following measuring methods.
1. Sound insulation performance According to the sound transmission loss measuring method in JIS A 1416 laboratory.
2. A sample was placed on a hot plate with a heat shielding performance of 150 ° C., a thermocouple was placed on the opposite side of the sample, and the surface temperature was measured for 60 minutes.
3. Maximum bending stiffness sample size: 150 × 50 mm, span: 100 mm, test speed: 20 mm / min.
The results of performance evaluation of these examples and comparative examples are as shown in FIG.
[0016]
The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and even if there is a design change or the like without departing from the gist of the present invention. Are included in the present invention.
[0017]
【The invention's effect】
As described above, according to the present invention, in the floor carpet installed on the trunk floor of an automobile, the floor carpet is composed of a nonwoven fabric made of short thermoplastic synthetic fibers, and a hard layer. The soft layer is sandwiched between two hard layers, and is a sound insulation / heat insulation structure and a trunk floor carpet for automobiles that serves as a weight support member. In addition to having thermal performance, the spare tire cover can be abolished, and the excellent effect of reducing the number of assembly steps for the operator can be obtained.
[Brief description of the drawings]
FIG. 1 is a diagram showing a configuration of an example and a comparative example.
FIG. 2 is a diagram showing the performance evaluation results of examples and comparative examples.

Claims (6)

In the floor carpet installed on the trunk floor of an automobile, the floor carpet is composed of a nonwoven fabric made of thermoplastic synthetic short fibers, and comprises a hard layer and a soft layer, and the soft layer is between two hard layers. A trunk floor carpet for an automobile which exists in a sandwiched form and serves as a sound insulation / heat insulation structure and a weight support member. The trunk floor carpet for automobiles according to claim 1, wherein the short fibers constituting one of the hard layers are colored before dyeing or spinning. The trunk for automobiles according to claim 1 or 2, wherein the nonwoven fabric comprises at least two kinds of short fibers mainly comprising a high softening point polyester staple and a low softening point polyester staple having a softening point lower by at least 20 ° C. Floor carpet. The trunk floor carpet for an automobile according to any one of claims 1 to 3, wherein the maximum bending load of the hard layer is 2 kgf or more, and the ratio of the maximum bending load of the hard layer to the soft layer is 10: 1 or more. The trunk floor carpet for automobiles according to claim 4, wherein the blending amount of the low softening point polyester staple contained in the hard layer is 40% or more. The trunk floor carpet for an automobile according to any one of claims 1 to 5, wherein a thickness obtained by laminating the hard layer and the soft layer is 10 to 30 mm.

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