JP6242635B2 - Vehicle floor spacer and manufacturing method thereof - Google Patents

Description

  The present invention relates to a vehicle floor spacer in which a skin material and a urethane foam are integrally molded by integral foaming of the skin and a method for manufacturing the same.

On the floor surface of a vehicle, a floor material called a vehicle floor spacer is disposed in order to mitigate an impact on an occupant's legs and to provide sound insulation.
As a conventional vehicle floor spacer, a carpet member is arranged on a cavity surface of a mold, and the carpet member is adhered to the surface of the urethane foam by integral foaming in which urethane foam raw material is injected into the mold and foamed. There is something.

  However, in the case of conventional vehicle floor spacers, the back surface of the carpet member made of non-foamed polyethylene resin is used to prevent the urethane foam material from oozing out onto the surface of the carpet member when the skin is integrally foamed. A material was provided to prevent the urethane foam raw material from penetrating into the carpet member. Therefore, the vehicle floor spacer has a problem that it becomes heavy due to the presence of the non-foamed backing material and a problem that the cost becomes high.

Japanese Patent Laid-Open No. 3-42237 JP-A-61-237630

  The present invention has been made in view of the above points, and it is an object of the present invention to provide a vehicle floor spacer capable of preventing the urethane foam raw material from seeping out from the skin material and being lightweight and capable of reducing the cost, and a method for manufacturing the same. .

According to a first aspect of the present invention, there is provided a vehicle floor spacer comprising a skin material and a urethane foam formed by adhering a urethane foam material to one surface of the skin material while the urethane foam material is in contact with the skin material. The material is composed of a two-layer nonwoven sheet, and one of the layers has a basis weight of 90 g / m ² or more and a fiber diameter of 2 to 4 d (denier), and the other layer has a basis weight of 100 g / m ² or more. any layer in the acrylic acid ester Te Le resin, characterized in that impregnated 35 g / m ² or more.

According to a second aspect of the present invention, in the first aspect, the one layer is on the urethane foam side, the other layer has a fiber diameter of 5d (denier) or more, and the acrylic acid ester is included in the one layer. Te Le resin, characterized in that impregnated 35 g / m ² or more.

According to a third aspect of the present invention, there is provided a vehicle floor in which a skin material is disposed on a cavity surface of a mold, and a urethane foam raw material is injected into the mold and foamed so that the skin material adheres to the surface of the urethane foam. In the method for producing a spacer, the skin material is composed of a two-layer nonwoven fabric sheet, and any one layer has a basis weight of 90 g / m ² or more and a fiber diameter of 2 to 4 d, and the other layer has a basis weight of 100 g / m ^2. and m ² or more, any of the layers in the acrylic acid ester Te Le resin, characterized in that impregnated 35 g / m ² or more.

A fourth aspect of the present invention, in claim 3, wherein one of the layers is said urethane foam feed side, wherein the other layer has a fiber diameter of more than 5d, the acrylic acid ester Te le to the layer of the one It is characterized by being impregnated with a resin of 35 g / m ² or more.

According to the invention of claim 1, the skin material is composed of a two-layer nonwoven fabric sheet, and since any one layer has a basis weight of 90 g / m ² or more having a fiber diameter of 2 to 4 d, fine fibers are densely packed. Furthermore, any layer is impregnated with 35 g / m ² or more of an acrylic ester resin. Therefore, the penetration of the urethane foam material into the skin material is controlled. And when the other layer is 100 g / m < ² > or more of fabric weights, it can prevent that a urethane foam raw material oozes out from a skin material. A skin material with a small total basis weight can prevent the uretafoam material from seeping out. Therefore, compared with the case where non-foamed polyethylene resin is used as a backing material, the weight can be reduced and the cost can be reduced. The non-foamed polyethylene resin backing material requires treatment such as corona discharge in order to provide adhesion to the urethane foam raw material, but since the skin material allows impregnation of the urethane foam raw material, No special treatment is required for bonding with urethane foam materials. Furthermore, the acrylic ester resin impregnated in the skin material also has an effect of improving flame retardancy. In addition, the layer which consists of a fiber diameter of 2-4d in the said skin material contains 80 weight% or more of fibers with a fiber diameter of 2-4d of the whole fiber.

According to the invention of claim 2, since one layer where the fine fibers are dense in the skin material is on the urethane foam raw material side and the acrylate resin is impregnated with 35 g / m ² or more, urethane It becomes difficult for the foam raw material to penetrate into the skin material, and the urethane foam raw material can be effectively prevented from seeping out from the surface of the skin material. Furthermore, since the other layer of the skin material on the outside of the vehicle floor spacer is made of a thick fiber having a fiber system of 5d or more, the wear resistance of the surface of the vehicle floor spacer is improved. In addition, the layer having a fiber diameter of 5d or more in the skin material includes 80% by weight or more of fibers having a fiber diameter of 5d or more.

  According to the invention of claim 3, it is possible to easily manufacture a vehicle floor spacer that can prevent the urethane foam raw material from seeping out from the skin material, has lightness and flame retardancy, and can reduce the cost. .

  According to the invention of claim 4, a vehicle floor that prevents the urethane foam raw material from seeping out from the skin material, is lightweight and flame retardant, can be reduced in cost, and has good surface wear resistance. The spacer can be easily manufactured.

It is sectional drawing of one Embodiment of the floor spacer for vehicles. It is sectional drawing which shows a part of manufacturing process in one Embodiment of the manufacturing method of the floor spacer for vehicles. It is sectional drawing which shows the product demolding process of a manufacturing process.

  A vehicle floor spacer 10 according to an embodiment of the present invention shown in FIG. 1 is arranged on the floor surface of a vehicle, and a urethane foam raw material is formed on the skin material 20 and one surface of the skin material 20. The urethane foam 30 is formed by foaming while contacting and adhering to the skin material 20.

The skin material 20 is composed of a two-layer nonwoven fabric sheet composed of an upper layer 21 and a lower layer 23. Any one of the upper layer 21 and the lower layer 23 has a basis weight of 90 g / m ² or more, preferably a basis weight of 90 g / m ² or more and 500 g / m ² or less, and the other layer has a basis weight. It is 100 g / m ² or more, preferably 100 g / m ² or more and 500 g / m ² or less. When the skin material 20 is configured in this manner, the thin urethane fiber material in one layer is dense, so that the viscous urethane foam raw material hardly oozes out of the skin material 20. One of the two layers is impregnated with an acrylic ester resin at 35 g / m ² or more, preferably 35 g / m ² or more and 100 g / m ² or less. Between the fibers of the surface material 20 is filled with the acrylic ester resin by impregnation with the acrylic ester resin, the urethane foam raw material becomes difficult to pass through the skin material 20, and the urethane foam raw material is more difficult to ooze out. . The surface of the skin material 20 may be impregnated with the acrylic ester resin by applying an emulsion of an acrylic ester resin to the surface of the skin material 20 or by applying an acrylic ester resin powder to the surface of the skin material 20. It can be carried out by spraying it on a hot roller or hot air.

In a more preferred embodiment of the skin material 20, the lower layer 23 on the urethane foam 30 side has a basis weight of 90 g / m ² or more and a fiber diameter of 2 to 4 d, and is impregnated with 35 g / m ² or more of an acrylate resin. It is the aspect made to do. When the skin material 20 is configured in this manner, the lower layer 23 in contact with the urethane foam raw material is dense with fine fibers and further impregnated with 35 g / m ² or more of the acrylic ester resin. It becomes difficult to soak into the skin material 20. And the exudation of a urethane foam raw material from the surface of the said skin material 20 can be prevented effectively by the basis weight of the said upper layer 21 which contact | connects a passenger | crew etc. being 100 g / m < ² > or more. Furthermore, it is preferable that the upper layer 21 has a fiber diameter of 5 d or more to improve wear resistance. The upper layer 21 and the lower layer 23 are integrated by bonding or needle punching.

The urethane foam 30 is foamed in a state where the urethane foam raw material is in contact with one surface of the skin material 20, in the illustrated example, the surface of the lower layer 23, and is integrally formed by adhering to the skin material 20. Yes, provided to improve sound absorption and shock absorption. The urethane foam raw material comprises a polyol, a polyisocyanate, a blowing agent and a catalyst such as, are those known to be foamed by the reaction of a polyol and a polyisocyanate to form a urethane foam density 40kg ^/ m ³ ~95kg / m 3 Those are preferred. The thickness of the urethane foam 30 is preferably about 3 mm to 50 mm. The urethane foam 30 is bonded and integrated with the skin material 20 by impregnation that occurs during foam molding of the urethane foam raw material.

An embodiment of a method for manufacturing the vehicle floor spacer 10 will be described. The manufacturing method of the said vehicle floor spacer 10 consists of a skin material arrangement | positioning process, a urethane foam raw material injection | pouring process, a foaming process, and a demolding process.
In the skin material placement step, the skin material 20 is placed on the cavity surface of the upper mold 43 of the mold 40 as shown in FIG. At that time, the skin material 20 has a fiber diameter of ² to 4 d (denier) and a basis weight of 90 g / m ² or more, and is a layer impregnated with 35 g / m ² or more of the acrylate resin, in the illustrated example. The lower layer 23 is preferably disposed on the cavity surface of the upper mold with the lower layer 23 facing downward. In addition, the said cavity surface is a rough surface according to the shape of the said floor spacer 10 for vehicles.

In the urethane foam raw material injection step, as shown in FIG. 2B-2, the urethane foam raw material 30 a is injected into the mold 40 in which the skin material 20 is disposed in the upper mold 43. The injection volume of the urethane foam raw material 30a is preferably an amount that the density of the urethane foam formed by foaming is ^{40kg / m 3 ~95kg / m 3} . After injecting the urethane foam raw material 30a into the mold 40 with the mold 40 opened, the lower mold 41 and the upper mold 43 are closed. In addition, when a raw material injection port (not shown) is formed in the mold 40, after placing the skin material 20 on the mold, the urethane foam raw material is molded from the raw material injection port with the mold closed. It can be molded by injecting it. The injected urethane foam raw material 30a includes one layer of the skin material 20, in the illustrated example, the lower layer 23 having a fiber diameter of ² to 4d (denier) and a basis weight of 90 g / m ² or more, and the acrylate ester Since the resin is impregnated with 35 g / m ² or more, the urethane foam raw material 30a is difficult to soak into the skin material 20.

In the foaming step, as shown in FIG. 2 (2-3), the urethane foam raw material 30a is foamed by the progress of the reaction in the mold 40 to form the urethane foam 30, and the skin during the foam molding is formed. The skin material 20 and the urethane foam 30 are bonded and integrated by impregnation into the material 20.
In the demolding step, as shown in FIG. 3, the mold 40 is opened, and the vehicle floor spacer 10 in which the skin material 20 and the urethane foam 30 are integrated is taken out.

The vehicle floor spacer 10 obtained in this way has a good appearance with no exudation of the urethane foam raw material 30a on the surface of the skin material 20. Further, since there is no non-foamed backing material, the weight is light and the cost can be reduced. Further, the vehicle floor spacer 10 is flame retardant, and the wear resistance can be further improved by setting the upper layer 21 to have a fiber diameter of 5 d or more and a basis weight of 100 g / m ² or more.

2 and 3 show the vehicle floor spacers of Examples 1 to 8 and Comparative Examples 1 to 5 using the skin materials shown in Tables 1 and 2 made of PET (polyethylene terephthalate) fibers. It was manufactured by the above manufacturing method using a mold. In addition, the structure of the fiber of the skin material includes 80% by weight or more of the fiber having the display fiber diameter (d). The manufactured vehicle floor spacer was 1 m × 1 m, and the thickness of the urethane portion was 20 mm. The density of the urethane foam is 50 kg / m ³ .

About the floor spacer for vehicles of each Example and each comparative example, combustibility, abrasion resistance, seepage resistance, and the whole weight were measured.
The combustibility was determined in accordance with the standard of FMVSS-302 (flame retardance of automobile interior materials). For the evaluation of flammability, hold the test piece horizontally, apply the flame of the burner to one end of the test piece for 15 seconds, evaluate the flammability after removing the flame according to the horizontal test method, and test after removing the flame. When a piece immediately self-extinguishes or the burning rate is 100 mm / min or less, it is considered acceptable, and when it exceeds 100 mm / min, it is regarded as unacceptable.
Wear resistance is determined in accordance with ASTM D3884. The surface of the surface material and the wear wheel are brought into contact with each other and rotated at a load of 500 gf (4.9 N) and a rotation number of 200 times / min. The test was rejected when there was significant fuzz, and the test was accepted when fuzz was not noticeable.
For the anti-bleeding resistance, three specimens were used, and for all three, the case where urethane exudation could not be visually confirmed on the surface of the skin material was ◎ (pass), and only one piece of urethane was coated on the surface of the skin material. If the other 2 pieces have a slight exudation, and the other 2 pieces cannot be visually confirmed, ○ (pass), and if two or more pieces of urethane can be visually confirmed, × (fail) It was.
The total weight was obtained by measuring the weight of the vehicle floor spacer of each example and each comparative example. For reference, the weight of a conventional vehicle floor spacer in which urethane foam was foamed by providing a backing material made of non-foamed polyethylene resin on the back surface of the carpet member was 2100 g.
In the present invention, bleed-out resistance and lightness (overall weight) are the first objectives, and if these are satisfied, the product is acceptable. Flame retardancy and wear resistance are secondary objectives.

As shown in Table 1, in all of Examples 1 to 8, the seepage resistance was acceptable (（or ○). In addition, Examples 1 to 8 had an overall weight of 1250 to 1300 g, which was lighter than a conventional vehicle floor spacer of 2100 g. The flammability, against the impregnation amount of acrylate resin is Examples 1-7 of 50~40g / ^{m 2} was passed, Example 8 of the amount impregnated 35 g / ^{m 2} is a at failure It was. Moreover, about abrasion resistance, although Example 1 and Example 2 whose upper layer fiber is 3d were disqualified, it was pass about Example 3-8 whose upper layer fiber was 6d or 5d. .

Comparative Example 1 was an example in which the acrylic ester resin was not impregnated in the configuration of Example 3, and the exudation resistance was x, the combustibility was not acceptable, and the wear resistance was acceptable. Comparative Example 2 was a case where the basis weight of the lower layer was 70 g / m ² less than the range of the present invention in the configuration of Example 3, and the seepage resistance was x, and the combustibility and wear resistance were acceptable. The comparative example 3 is a case where the acrylic ester resin is not impregnated in the configuration of the example 1, and was exudation resistance ×, combustibility failure, and abrasion resistance failure. In Comparative Example 4, the two skin layers were larger than 2 to 4d (denier), and the exudation resistance x, combustibility and wear resistance were acceptable. Comparative Example 5 is a case where the skin material is composed of one layer, and one layer is impregnated with 50 g / m ² of an acrylate resin, and the seepage resistance x, the flammability and the wear resistance are acceptable. It was.

  As described above, all of the examples passed the anti-bleeding property and lightness (overall weight), whereas in the comparative examples, the exudation of urethane was confirmed on the surface of the skin material, and the anti-bleeding was observed. Sex was rejected.

DESCRIPTION OF SYMBOLS 10 Vehicle floor spacer 20 Skin material 21 Upper layer 23 Lower layer 30 Urethane foam 30a Urethane foam raw material 40 Mold 41 Lower mold 43 Upper mold

Claims (4)

In a vehicle floor spacer comprising a skin foam and a urethane foam formed by adhering to the skin material while the urethane foam raw material is in contact with one surface of the skin material,
The skin material is composed of a two-layer nonwoven sheet, and one of the layers has a basis weight of 90 g / m ² or more and a basis weight of ² to 4 d, and the other layer has a basis weight of 100 g / m ² or more. the vehicle floor spacer, characterized in that the acrylic acid ester Te Le resin impregnated 35 g / m ² or more Kano layers. Wherein one of the layers is the urethane foam side, said other layer has a fiber diameter of more than 5d, the acrylic acid ester Te Le-based resin layer of the one impregnated 35 g / m ² or more The vehicle floor spacer according to claim 1. In the method of manufacturing a vehicle floor spacer in which the skin material is bonded to the surface of the urethane foam by placing the skin material on the cavity surface of the mold and injecting and foaming urethane foam raw material into the mold,
The skin material is composed of a two-layer nonwoven sheet, and one of the layers has a basis weight of 90 g / m ² or more and a basis weight of ² to 4 d, and the other layer has a basis weight of 100 g / m ² or more. the vehicle floor spacer manufacturing method which is characterized in that the acrylic acid ester Te Le resin impregnated 35 g / m ² or more Kano layers. Wherein one of the layers is said urethane foam feed side, said other layer has a fiber diameter of more than 5d, the acrylic acid ester Te Le-based resin layer of the one impregnated 35 g / m ² or more The manufacturing method of the floor spacer for vehicles of Claim 3 characterized by these.

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