JP4839283B2 - Soundproof carpet, manufacturing method thereof, and manufacturing apparatus - Google Patents

Description

The present invention is, for example, a carpet or mat laid on the floor of a vehicle such as an automobile, train or aircraft, a carpet or mat laid on the floor of a building or hallway, a chair mat for computer operation, a room entrance / exit Floor mats to be laid on the floor, floor mats to be laid in elevators and in front of elevator doors , soundproof carpets applied to entrance mats, etc. The present invention relates to a soundproof carpet having a sound absorbing effect, a manufacturing method thereof, and a manufacturing apparatus .

  Conventionally, for example, a floor carpet having a felt layer or a non-woven fabric layer and excellent in sound absorption performance is laid on the floor of an automobile.

  On the other hand, the automobile mat placed on the floor carpet is generally composed of a fiber base material in which a pile is driven into a nonwoven fabric and a backing layer formed on the back surface of the fiber base material.

  However, the backing layer in the car mat is made of a synthetic resin such as vinyl chloride resin and functions as a sound insulation layer. When this car mat is placed on a floor carpet, wind noise or the like is generated. Noise from the outside of the vehicle is rebounded by the backing layer of the automobile mat, and sufficient measures have not been taken for noise from outside the vehicle.

  Similarly, for carpets and mats laid on the floors of buildings and corridors, the backing layer on the back of the fiber base is a sound insulation layer, and the noise transmitted from the top surface of the carpet is rebounded. As a result, sufficient sound absorption measures were not taken.

Conventionally, in view of such circumstances, a sound-absorbing laminated interior material in which a sound-absorbing material is laminated on the lower surface of a surface material via a surface material and a backing material, and a plurality of holes are perforated. It has been proposed (see Patent Document 1).
Japanese Patent Laid-Open No. 62-184947

  The present invention has been made in view of the above technical problems, and has as its object to provide a soundproof carpet having excellent sound absorbing performance and a method for producing the same.

  In order to achieve the above object, the invention according to claim 1 and claim 2 is a soundproof carpet in which a backing layer is formed on the back side of a fiber base material, wherein a refrigerant is introduced into the inside of the mold and the surface is backed. Using a flat press machine with a pressing die provided with needles for forming a large number of holes in the layer, or while introducing a refrigerant into the interior and providing needles for forming a large number of holes in the backing layer on the surface A plurality of through holes are formed in the backing layer using the engraving roll and the pressing roll that presses the engraved roll, and at the same time, the fiber base material and the backing layer are integrated by hot pressing and cooled immediately thereafter. The gist of the sound-proof carpet obtained by fixing the shape of the through-holes of the backing layer.

  The invention according to claim 3 and claim 4 is a flat having a pressing mold in which a backing layer is formed and then a coolant is introduced into the pressing mold and needles for forming a large number of holes in the backing layer are provided on the surface. The backing layer is formed using an engraving roll provided with a needle for forming a large number of holes in the backing layer on the surface and a pressing roll that presses the surface using a press machine or a refrigerant introduced therein. A plurality of through holes are formed at the same time, the fiber base material and the backing layer are integrated by hot pressing, and the shape of the through holes of the backing layer is fixed by cooling immediately after that. The gist of the method is “manufacturing the carpet”.

The invention according to claims 5 and 6 is “a soundproof carpet manufacturing apparatus in which a fiber base material and a backing layer are integrated by heat pressing, wherein the apparatus has a coolant introduced into the inside of the mold and a surface. A flat press machine having a pressing die provided with needles for forming a large number of holes in the backing layer, and at the same time a large number of through holes are formed in the backing layer, the fiber base material and the backing layer are The gist of the apparatus is “a soundproof carpet manufacturing apparatus” which is heat-pressed and cooled immediately thereafter to fix the shape of the through-holes of the backing layer.

The present invention uses a flat press machine having a pressing die provided with a needle for forming a large number of holes in the backing layer on the surface thereof, or introduced into the inside of the pressing die. Using a sculpture roll provided with needles for forming a large number of holes in the backing layer on the surface and a pressing roll for pressing the same, a large number of through holes are formed in the backing layer and at the same time a backing with the fiber base material a layer since then integrated by heat pressing, soundproofing carpet formed of a fixed hole shape of the through hole of the backing layer by cooling immediately thereafter, its manufacturing method and manufacturing apparatus, sound absorption by the through hole The entire sound absorption level that can be achieved can be secured, and the planned sound can be reliably absorbed.

  Next, the invention according to each claim configured as described above will be described according to the embodiments shown in the drawings. FIG. 1 shows an example of a soundproof carpet according to claim 1. The soundproof carpet 10 shown in FIG. 1 is laid on the floor surface of a house or a car interior, and has a function of absorbing and removing static electricity charged on the human body in addition to soundproofing performance. .

  The soundproof carpet 10 forms a fiber base 16 by laminating discharge paper 13 having a function of discharging static electricity on a nonwoven fabric 12. A conductive pile yarn 14 including conductive fibers 14b is driven into the fiber base 16 so as to be substantially U-shaped from the nonwoven fabric 12 side, and a layer 15 made of SBR is provided on the discharge paper 13 side to provide the pile yarn. 14 is stopped.

  In the case of the fiber substrate 16 shown in FIG. 1, antibacterial deodorant particles in which the photocatalyst particle surface such as titanium, cerium, zinc and copper is coated with a fluorine-based porous layer are attached to the fiber surface as the nonwoven fabric 12 constituting the base fabric. Non-woven fabric with antibacterial properties such as non-woven fabric containing antibacterial deodorant fibers, or non-woven fabric that has been applied or sprayed with a binder with a conventionally known antibacterial agent and adhered to the surface of the constituent fibers. It absorbs and decomposes or removes it.

  The conductive fibers 14b included in the conductive pile yarn 14 are not particularly limited, and for example, inorganic fibers such as carbon fibers, metal fibers, and conductive ceramic fibers, and synthetic fibers are used as main materials, and copper fibers are formed on the surface of the fibers. And plating fibers plated with metals such as silver, aluminum, and the like, fibers in which metals such as copper, silver, and aluminum are kneaded on the fiber surface, or fibers containing conductive resin in the fiber component, etc. it can.

  When the human body comes into contact with the carpet 10, the soundproof carpet 10 instantaneously guides the static electricity charged in the human body to the carpet 10 side by the conductive fibers 14 b included in the pile yarn 14, and discharge paper 13 in the carpet 10. The air is discharged by the air. A part of the static electricity is discharged in the air through the discharge paper 3 and through the conductive fibers 14 b included in the pile yarn 14.

  In the carpet 10, a backing layer 21 is formed on the fiber base 16 on the layer 15 side made of SBR. The backing layer 21 has four layers in the order of the open-cell SBS foamed resin layer 17 with filler, the felt layer 18 with heat-bonding fibers, the SBS resin layer 19 and the urethane home 20 on the lower surface of the SBR layer 15. Consists of.

  Finally, in the soundproof carpet 10, a large number of through holes 30 having a diameter of about 1.5 mm are made open through the front and back of the soundproof carpet 10. By forming such through-holes 30, as shown in FIG. 2, especially when looking at the foamable resin layers 17 and 20, an infinite number of sound absorbing holes 31 are formed on the inner surface of each through-hole 30. Yes. Since the SBS foamed resin layer 17 and the urethane home 20 are made by foaming resin, each foamed portion is broken by forming the through hole 30 and is opened to the through hole 30. The infinite number of sound absorbing holes 31 opened (exposed) in the through hole 30 reflect the sound that has entered through the opening of the through hole 30 in the through hole 30, and literally have a sound absorbing effect. It will be demonstrated.

  Next, the soundproof carpet 10 shown in FIG. 3 will be described. The carpet 10 has an excellent sound absorbing performance as a soundproof carpet laid on the floor surface of the interior of a house or a vehicle interior of a car, and in the same manner as the carpet 10 shown in FIG. It has a function of absorbing and removing.

  In this soundproof carpet 10, the non-woven fabric 102 having antibacterial properties is used as the base fabric in the same manner as shown in FIG. 1, and it effectively absorbs bad odors in the room and decomposes or removes them. Yes.

  A felt paper 200 is formed by laminating a discharge paper 103 having a function of discharging static electricity on the nonwoven fabric 102, superposing a metal foil 22 on the discharge paper 103 side, and further superposing a number of low weight felts on the metal foil 22 side. The fiber base material 104 is obtained by laminating the layers.

  A pile yarn 14 containing conductive fibers 14b is driven into the fiber base material 104 from the front (nonwoven fabric 102) side of the fiber base material 104 so as to be substantially U-shaped, and the back side of the fiber base material 104 (felt layer 200). A foamed resin layer 201 (backing layer) made of SBS is formed on the side.

  When the human body comes into contact with the carpet 10, the soundproof carpet 10 instantaneously guides the static electricity charged in the human body to the carpet 10 side by the conductive fibers 14 b included in the pile yarn 14, and discharge paper 13 in the carpet 10. However, since each conductive pile yarn 14 is in an electrically conductive state through the metal foil 22, there is a break in a part of the conductive fiber 14b. Even so, static electricity is instantaneously and uniformly guided to the carpet 10 through the metal foil 22. A part of the static electricity is discharged in the air through the discharge paper 3 and the metal foil 22 through the conductive fibers 14 b included in the other pile yarns 14.

  Finally, in this soundproof carpet 10, a large number of through-holes 30 having a diameter of about 1.5 mm are pierced through the front and back surfaces. By forming such through-holes 30, as shown in FIG. 2, especially when looking at the foamable resin layer 201, an infinite number of sound absorbing holes 31 are formed on the inner surface of each through-hole 30. Since the foamed resin layer 201 is obtained by foaming a resin, each foamed portion is broken by forming the through hole 30 and opens to the through hole 30. The infinite number of sound absorbing holes 31 opened (exposed) in the through hole 30 reflect the sound that has entered through the opening of the through hole 30 in the through hole 30, and literally have a sound absorbing effect. It will be demonstrated.

  When providing the foamed resin layer 201 on the back side of the fiber substrate 104, the apparatus shown in FIGS. 4 and 5 is used. The apparatus shown in FIGS. 4 and 5 is provided with a recess 301 and a groove 302 for forming a misalignment preventing projection 203 and an unevenness (not shown) on the foamed resin layer 201 shown in FIG. A protruding engraving roll 300 and a pressing roller 304 are provided.

  An ultrasonic generator (not shown) is connected to the engraving roll 300, and the engraving roll 300 functions as a horn. Further, a cooling gas such as nitrogen is introduced into the engraving roll 300 so that the roll surface is instantaneously cooled.

  Then, ultrasonic waves are generated while the fiber base material 104 and the foamed resin layer 201 are passed between the engraving roll 300 and the pressing roller 304, so that the fiber base material 104 and the foamed resin layer 201 are heated. While pressing and integrating, a protrusion 203 for preventing misalignment and unevenness (not shown) are formed on the foamed resin layer 201.

  At the same time, the needle 303 on the roll surface penetrates the fiber base material 104 and the foamed resin layer 201 to form a through hole 30 penetrating the front and back of the soundproof carpet 10.

  Immediately after the hot pressing and drilling, the roll surface is instantaneously cooled by the cooling gas introduced into the roll, and the misalignment prevention projection 203 and the unevenness (not shown) and the through hole 30 The shape is fixed.

Further, a needle is provided on the pressing die of the flat press machine in substantially the same manner as the engraving roll 300 described above, and an ultrasonic generator is connected to the pressing die so that the pressing die acts as a horn. It is also possible to introduce a cooling gas such as nitrogen into the mold so that the mold surface is cooled instantaneously.

  In this case, similar to the engraving roll 300 and the pressure roller 304 described above, the fiber base material 104 and the foamed resin layer 201 that are cut into a raw shape or in a predetermined shape are hot-pressed by ultrasonic waves to obtain the foamed resin layer 201. The hole shape can be fixed by forming a through hole 30 penetrating through the front and back surfaces and then cooling.

  The soundproof carpet 10 shown in FIGS. 1 and 3 has a plurality of through-holes 30 penetrating the front and back, as described above, so that the sound-absorbing carpet 10 has a felt layer and a nonwoven fabric layer on the floor surface. When applied as a rug laid on a carpet with excellent performance, the noise from the top of the rug, such as wind noise, is transmitted through the numerous through holes 30 to the carpet on the floor and absorbed and removed by the carpet. It has come to be.

  In the soundproof carpet of the present invention, innumerable holes of different sizes and shapes are formed in the fiber base material and the backing layer constituting the carpet, and the front and back of the soundproof carpet penetrate through these innumerable holes. Various types of sound having different frequencies transmitted to the carpet are effectively absorbed and removed by each layer and each hole.

  The scope of the present invention is defined in “Claims”, and all modifications and forms included in the scope can be adopted.

It is a principal part expanded sectional view of the soundproof carpet obtained by the manufacturing method and manufacturing apparatus of this invention. It is a principal part expanded sectional view which shows the through-hole of the soundproof carpet. It is a principal part expanded sectional view which shows another example of the soundproof carpet obtained by the manufacturing method and manufacturing apparatus of this invention. It is a schematic diagram which shows the formation apparatus of the through-hole of the soundproof carpet shown in FIG. It is a principal part enlarged view of the same apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Soundproof carpet 16, 104 ... Fiber base material 13 ... Discharge paper 30 ... Through-hole 31 ... Sound absorption hole 21, 201 ... Backing layer

Claims (6)

A soundproof carpet in which a backing layer is formed on the back side of the fiber substrate,
Refrigerant is introduced into the inside of the mold, and the surface is backed by using a flat press machine having a mold provided with needles for forming a large number of holes in the backing layer, or while the refrigerant is introduced into the inside of the mold. Using the engraving roll provided with needles for forming a large number of holes in the layer and the pressing roll that presses this,
By simultaneously forming a large number of through holes in the backing layer by hot pressing the fiber substrate and the backing layer, and cooling immediately after that, fixing the hole shape of the through holes of the backing layer The resulting soundproof carpet.   2. The soundproof carpet according to claim 1, wherein the backing layer comprises an open cell foamed resin layer. Forming a backing layer,
Next, the refrigerant is introduced into the inside of the mold and the surface is introduced with a flat press having a mold provided with needles for forming a large number of holes in the backing layer, or the surface is introduced with the refrigerant. The engraving roll provided with needles for forming a large number of holes in the backing layer and the pressing roll pressing the same are used to form a large number of through holes in the backing layer, and at the same time, the fiber substrate and the backing layer The method for producing a soundproof carpet is characterized in that the hole shape of the through-holes of the backing layer is fixed by heat-pressing and integrating immediately after cooling.   4. The method for producing a soundproof carpet according to claim 3, wherein a number of through holes are formed in the backing layer and a protrusion for preventing displacement is formed. A soundproof carpet manufacturing apparatus in which a fiber base material and a backing layer are integrated by heat pressing,
The apparatus comprises a flat press machine having a pressing die in which a coolant is introduced into the pressing die and a needle for forming a large number of holes in the backing layer is provided on the surface.
At the same time that a large number of through holes are formed in the backing layer, the fiber base material and the backing layer are hot-pressed and cooled immediately thereafter to fix the shape of the through holes of the backing layer. A soundproof carpet manufacturing apparatus characterized by the above. Together with the ultrasonically generating device connected press die is to act as a horn pressing die, by introducing a cooling gas, such as the embossing die inside nitrogen, that the mold surface is to be cooled instantaneously The apparatus for producing a soundproof carpet according to claim 5 .

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