JPH0635269B2 - Method for producing multilayer mat for automobile and sound insulating mat material used in the method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing an automobile multi-layer mat for forming a multi-layer mat laid on the floor of an automobile, and a sound insulating mat material used in this method.

[Conventional technology]

Conventionally, as shown in Japanese Utility Model Publication No. 59-7152, there is a multilayer mat laid on the floor of an automobile. This multi-layer mat is integrally laminated with a carpet material, a sound insulating mat material, etc., and has the effects of soundproofing, vibration damping, and heat insulation, as well as improving the tread comfort and appearance.

That is, for example, as shown in FIG.
Is composed of a carpet material 2 and a sound insulating mat material 3, and this carpet material 2 has a raised portion 4 as shown in FIG.
And a base material 5 for supporting the base of the napped portion 4, and a polyethylene thin layer 6 fused to the base material 5 as a backing material.
Composed of and. As shown in FIG. 8, the sound insulating mat material 3 is composed of a sound insulating mat 7 and an adhesive layer 8 which is pressure-fused to the sound insulating mat 7 as a medium layer. Then, the carpet material 2 and the sound insulating mat material 3 are pressure-bonded to each other with the adhesive layer 8 as a medium layer to be molded into a predetermined shape.

When manufacturing such a multilayer mat 1, the sound insulating mat material 3 is usually stored in a supply unit of the sound insulating mat material 3 in a state of being stacked in advance, and a suction conveyer or the like is fed from the supply unit one by one. It is designed to be transported to the multi-layer mat molding section.

[Problems to be Solved by the Invention]

However, in the conventional sound insulating mat material 3 for a multi-layered mat for an automobile, since the surfaces of the sound insulating mat 7 and the adhesive layer 8 are formed to be substantially flat, when a plurality of sound insulating mat materials 3 are stacked in the supply section. , The sound-insulating mat material 3 comes into close contact.

For this reason, when a suction carrier etc. lifts the uppermost sound insulation mat material from the supply section, the sound insulation mat material stacked under this uppermost sound insulation mat material is also lifted at the same time, and this sound insulation mat material is sucked up. There is a problem that it falls during the movement to the upper part of the multi-layered mat molding portion by a carrier or the like, or it is superposed on the upper surface of the carpet material 2 in the state of being in close contact with it and causes a processing defect.

The present invention solves the above problems, and a method of manufacturing a multilayer mat for an automobile using a sound insulating mat material that can be easily separated without adhering to each other even when a plurality of sound insulating mat materials are stacked, and a method thereof. The purpose is to provide a sound insulating mat material to be used.

[Means for Solving the Problems]

The present invention according to claim 1 is formed by a sound insulating mat and an adhesive layer joined to one surface thereof, and the convex portion is scattered by forming the surface of the adhesive layer or the anti-adhesive side layer of the sound insulating mat in an uneven shape. A sound-insulating mat material provided in a dot shape is used, and the sound-insulating mat material is stored in the supply unit in a state of being stacked with the uneven side facing downward, and the sound-insulating mat material is adsorbed from the supply unit by a suction carrier. And is conveyed to the multilayer mat molding section, and the above-mentioned sound insulation mat material is pressure-bonded to the carpet material at this multilayer mat molding section.

The present invention according to claim 2 is formed by a sound insulating mat and an adhesive layer bonded to the surface of the sound insulating mat and serving as a medium for adhering to the carpet material. The surface of the adhesive layer is fixed to the back surface of the carpet material. In the sound insulating mat material of the multi-layered automotive mat as described above, by forming the surface of the adhesive layer in a concavo-convex shape, a convex portion serving as a contact portion to a corresponding surface when a plurality of sound insulating mat materials are stacked on the surface is formed. The parts are dispersed.

[Action]

According to the present invention described in claim 1, a plurality of sound insulating materials are used in a state in which the contact area between the sound insulating mat materials is reduced by utilizing the uneven shape formed on the surface of the sound insulating mat on the side opposite to the adhesive layer. From the supply section where the mat materials are stacked,
The sound insulating mat material is surely conveyed one by one to the multi-layer mat molding section where the multi-layer mat molding process is repeated, and this section mat material is pressure-bonded to the petpet material in the multi-layer mat molding section, whereby a multi-layer mat for automobiles is obtained. Will be manufactured.

According to the present invention described in claim 2, since the convex portions are dispersedly formed on the surface of the adhesive layer fixed to the back surface of the sound insulating mat, when the sound insulating mat materials are stacked,
The presence of the convex portions prevents the sound insulating mats from being brought into close contact with each other. Further, when the sound insulating mat material is fixed to the back surface of the carpet material, the front surface of the adhesive layer is bonded to the back surface of the carpet material to prevent the convex portion from being exposed to the outside.

〔Example〕

FIG. 1 shows a sound insulating mat material 3 used in the method for manufacturing a multilayer mat for an automobile according to the present invention.

This sound insulation mat material 3 is similar to that shown in FIG.
And an adhesive layer 8 made of a thermoplastic resin material and bonded to one surface thereof. The sound insulation mat 7 absorbs and reflects noise from the engine, and has a specific gravity of, for example, 0.
It is composed of a polyvinyl chloride sheet having a thickness of 5 to 3.0 and a thickness of 0.5 mm to 6.0 mm. In order to increase the specific gravity of this sound insulation mat 7, lead oxide, iron oxide
Mix powder with high specific gravity such as calcium carbonate. In addition to the filler, the sound insulation mat 7 includes a plasticizer, a stabilizer,
It is formed from a resin composition part containing a foaming agent, a pigment and the like. Further, the anti-adhesion layer side surface 71 of the sound insulating mat 7 is formed substantially flat as in the conventional case, so that the suction conveyance machine or the like can surely suck the anti-adhesion layer side surface 71.

The adhesive layer 8 serves as a medium for press-bonding the polyethylene thin layer 6 of the carpet material 2 and the sound insulating mat material 3 when integrally molding the multilayer mat 1. In addition, the surface 8 of the adhesive layer 8
1 is formed in a concavo-convex shape such that a large number of convex portions 82 exist in a dispersed manner. The area of the upper surface of the convex portion 82 is 1 mm ²
It is preferable that the height difference of the unevenness is about 0.1 mm to 0.8 mm.

Further, the shape of the upper surface of the convex portion 82 may be hemispherical, rectangular, circular or any other shape. Further, the ratio of the convex portion 82 and the concave portion of the uneven shape is such that when the sound insulating mat material 3 is stacked, only the convex portion 82 is in contact with the corresponding surface and the concave portion is not in contact, and the sound insulating mat material 3 is The number may be large or small as long as it can be easily separated.

A method of manufacturing the sound insulating mat material 3 will be described with reference to FIG.

First, the sound insulation mat 7 is rolled to a predetermined thickness (0.5 mm to 6.0 mm) by the rolling rolls 9 and 10, and the pressure roller 1
Lead to 1. At the same time, the adhesive layer 8 derived from the original fabric 12 is guided to the embossing roller 13 having irregularities formed on the outer peripheral portion of the roller. Then, in the heated state, the sound insulation mat 7
And the adhesive layer 8 with the pressure roller 11 and the embossing roller 1
3. Pressing with 3. Furthermore, the embossing roller 13
Simultaneously with the pressure bonding, the convex portion 82 is continuously formed on the surface 81 of the adhesive layer 8.

After that, the sound insulating mat material 3 is applied to the cooling roller step 14
It is cooled to, and then is led to a cutting step 15, where it is cut into a predetermined size.

Next, a method for manufacturing the multilayer mat 1 according to the present invention using the sound insulating mat material 3 will be described with reference to FIG.

The carpet material 2 is fed from the raw fabric 16 with the polyethylene thin layer 6 as the upper surface, and the carpet material 2 is guided to the multilayer mat molding portion 17. Next, the sound insulating mat material 3 with the adhesive layer 8 facing down is superposed on the upper surface of the carpet material 2, and is heated by the heater 18 from the sound insulating mat 7 side of the sound insulating mat material 3, and further the two layers in the above heating state. Material 2,
3 between the pair of molds 19, and then the molds 19 are pressed to press the materials 2 and 3 together.
At the same time, the multi-layer mat 1 is molded into a predetermined shape and molded.

As shown in FIG. 4, the sound-insulating mat material 3 to be pressure-bonded to the carpet material 2 in the multi-layer mat molding section 17 is stacked on the supply section 21 and conveyed to the multi-layer mat molding section 17 by the suction conveyance machine 20. .

That is, the sound insulating mat material 3 is applied to the surface 81 of the adhesive layer 8.
After being stacked on the supply unit 21 with the
The suction carrier 20 operates and the cylinder 2 of the suction carrier 20
The suction section 202 provided at the tip of 01 descends, and the suction section 202 sucks the uppermost sound-insulating mat material 31 from the supply section 21. As shown in FIG. 5, each of the sound insulating mat materials 3 stacked in the supply section 21 is in contact with the anti-adhesive layer side surface 71 of the lower sound insulating mat 7 only at the convex portion 82, and the adhesive layer The contact area is smaller than that in the case of stacking the sound insulating mat materials whose surfaces are substantially flat. Therefore, when the suction transporter 20 adsorbs and lifts the sound insulating mat material 3, each sound insulating mat material 3 is easily separated.

Then, the cylinder 201 returns to the state before the operation and the sound insulating mat material 31 is lifted. Next, the suction transporter 20 moves along the rails 23 arranged on the pedestal 22, and reaches the upper portion of the carpet material 2 guided to the multilayer mat molding unit 17. Then, the cylinder 201 operates again to lower the suction part 202, and the sound insulating mat material 31 is placed on the upper surface of the carpet material 2 by the suction part 202. At the same time, the suction part 202 is connected to the sound insulating mat material 31.
Of the sound insulation mat material 31 from the suction part 202
To leave. As a result, the sound insulating mat material 31 and the carpet material 2 are in a state of being superposed on each other.

Thereafter, as described above, the multilayer mat molding portion 17 heats and presses the carpet material 2 and the sound insulation mat material 3 to mold the multilayer mat 1. At this time, the convex portion 82 of the adhesive layer 8 is pressed. Disappears when is added. As a result, the carpet material 2 and the sound insulating mat material 3 are completely bonded.

Then, the conveyance of the sound insulating mat material 3 from the supply unit 21 and the molding process in the multilayer mat molding unit 17 are repeated, whereby the multilayer mat 1 is efficiently mass-produced. Although the adhesive layer 8 is made of a thermoplastic resin material in the above embodiment, it may be made of a fiber thin layer having a thickness of 2 mm or less.

Further, when the unevenness is formed on the surface 81 of the adhesive layer 8 as described above, when the sound insulating mat material 3 is fixed to the back surface of the carpet material 2, the surface 81 of the adhesive layer 8 is formed.
Is bonded to the back surface of the carpet material 2 to prevent the convex portion 82 from being exposed to the outside, and the multilayer mat 1 for automobiles
Can be prevented from deteriorating the appearance.

As the carpet material 3 used in the method for manufacturing a multilayer mat for automobiles, a material in which the surface of the adhesive layer 8 is formed to be substantially flat and the surface 71 of the sound insulating mat 7 opposite to the adhesive layer is formed to be uneven is used. You may. The concavo-convex shape in this case can be formed by changing the pressure roller 11 to an embossing roller and the embossing roller 13 to a pressure roller in FIG. In the manufacture of the multi-layer mat 1, the sound insulating mat material 3 is stacked on the supply part 21 with the surface 71 of the sound insulating mat 7 having the above-mentioned uneven shape facing the non-adhesive layer side facing downward. The surface 81 of the adhesive layer 8 may be suctioned by the suction transporter 20 and transported to the molding unit, and may be heat-molded.

〔The invention's effect〕

INDUSTRIAL APPLICABILITY As described above, the present invention provides a multilayer structure using the sound insulating mat material formed on the adhesive layer of the sound insulating mat material or on the surface of the sound insulating mat on the anti-adhesive layer side and stored with the uneven surface facing downward. Since the mat is manufactured, when the sound-insulating mat material is sequentially transported from the supply part and the molding process is repeated in the multi-layer mat molding part to mass-produce the multi-layer mat, the multi-layer mat caused by the poor conveyance of the sound-insulating mat material is produced. There is an advantage that it is possible to prevent the deterioration of the operating rate of the molding part and to improve the productivity of the multilayer mat.

Further, according to the configuration in which the uneven shape is formed on the surface of the adhesive layer constituting the sound insulating mat material, when the sound insulating mat material is fixed to the back surface of the carpet material, the surface of the adhesive layer is bonded to the back surface of the carpet material. As a result, it is possible to prevent the protrusions from being exposed to the outside, and it is possible to prevent the appearance of the multilayer mat for automobiles from being deteriorated.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view of the sound insulation mat material, FIG. 2 is a view for explaining a method of manufacturing the sound insulation mat material of FIG. 1, and FIG.
FIG. 4 is a diagram for explaining an embodiment of a method for producing a multilayer mat according to the present invention, FIG. 4 is a diagram for explaining a method for superimposing a sound insulating mat material on a carpet material by using a suction carrier, and FIG. The figure is a partial cross-sectional view showing a state in which the sound insulating mat materials of FIG. 1 are stacked, FIG. 6 is a partial cross-sectional view of a conventional multilayer mat, and FIG. 7 is a partial cross-sectional view of the carpet material of FIG. 6, and FIG. FIG. 7 is a partial cross-sectional view of the sound insulation mat material of FIG. 6. 1 ... Multilayer mat, 2 ... Carpet material, 3 ... Sound insulation mat material, 7 ... Sound insulation mat, 8 ... Adhesive layer, 13 ...
... Embossing roller, 17 ... Multi-layer mat molding part, 21 ...
... Supply unit, 71 ... Surface of anti-adhesion layer side of sound insulation mat, 81
... the surface of the adhesive layer, 82 ... the convex portion of the adhesive layer.

Claims (2)

[Claims] 1. A sound-insulating mat and an adhesive layer bonded to one surface of the sound-insulating mat. The surface of the adhesive layer or the anti-adhesive side layer of the sound-insulating mat is formed in a concavo-convex shape so that the convex portions are provided in a dotted pattern. The sound insulating mat material is stored in the supply unit in a state where a plurality of the sound insulating mat materials are stacked with the concave and convex sides facing downward, and the sound insulating mat material is adsorbed from the supply unit by a suction conveyor to form a multilayer mat molding. A method for producing a multilayer mat for an automobile, which is characterized in that the sound insulating mat material is conveyed to a section and the sound insulating mat material is pressure-bonded to the carpet material in the multilayer mat molding section. 2. A sound-insulating mat and an adhesive layer which is bonded to the surface of the sound-insulating mat and serves as a medium for adhering to the carpet material. The surface of the adhesive layer is fixed to the back surface of the carpet material. A sound-insulating mat material for an automobile multi-layer mat, wherein the surface of the adhesive layer is formed in a concavo-convex shape so that a convex portion which becomes a contact portion with a corresponding surface when a plurality of sound-insulating mat materials are stacked is formed on the surface. The sound-insulating mat material used in the method for producing an automobile multilayer mat according to claim 1, wherein the sound-insulating mat material is dispersed.