Automobile floor carpet and method for manufacturing the same

• US 20070178794A1
• Filed: 01/31/2007
• Published: 08/02/2007
• Est. Priority Date: 02/02/2006
• Status: Active Grant

• Current Assignee: Suminoe Textile Co., Ltd.
• Original Assignee: Suminoe Textile Co., Ltd.
• Inventors: Nishio, Shigenori, Hattori, Taro
• Granted Patent: US 7,846,282 B2
• Time in Patent Office: Days
• US Class Current: 442/394
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2266/0221 Vinyl resin
• CPC Class Codes: B32B 2266/0242 Acrylic resin
• CPC Class Codes: B32B 2266/025 Polyolefin vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2471/02 Carpets
• CPC Class Codes: B32B 2471/04 Mats
• CPC Class Codes: B32B 25/045 of foam
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60N 3/042 : of carpets B60N3/046, B60N3/048 take precedence
• CPC Class Codes: B60N 3/048 : characterised by their structure
• CPC Class Codes: D06N 2205/04 : Foam
• CPC Class Codes: D06N 2205/08 : Microballoons, microcapsules
• CPC Class Codes: D06N 2209/025 : Insulating, sound absorber
• CPC Class Codes: D06N 2211/263 : Cars
• CPC Class Codes: D06N 7/0076 : the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
• CPC Class Codes: Y10T 428/23986 : With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/23993 : Composition of pile or adhesive
• CPC Class Codes: Y10T 442/651 : Plural fabric layers
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet

Abstract

In some embodiment, a method of manufacturing an automobile floor carpet comprises a step of pressing a nonwoven fabric 4, an adhesive film 3 obtained immediately after extruding thermoplastic resin having a melt flow rate of 10 to 1,000 g/10 min from an extruder 20, and a surface skin material 2 piled together in this order with a pair of rollers 21 and 22. With this manufacturing method, an automobile floor carpet excellent in sound absorption performance and also excellent in sound insulation performance can be manufactured.

Claims

1. A method of manufacturing an automobile floor carpet, comprising the step of:

pressing a nonwoven fabric, an adhesive film obtained immediately after extruding thermoplastic resin having a melt flow rate of 10 to 1,000 g/10 min from an extruder and a surface skin material piled together in this order with a pair of rollers.

2. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein the thermoplastic resin contains at least one foaming ingredient selected from the group consisting of an inorganic foaming agent, an organic foaming agent and a thermal expansion microcapsule.

3. The method of manufacturing an automobile floor carpet as recited in claim 2, wherein the adhesive film obtained immediately after the extrusion is a film having a foaming rate of 1.1 to 5.

4. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein the thermoplastic resin contains filler.

5. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein the melt flow rate of the thermoplastic resin is 100 to 1,000 g/10 min.

6. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein the adhesive film is 50 to 500 g/m² in weight per unit area.

7. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein the nonwoven fabric is 0.1 to 30 decitex in fineness of constituent fiber and 50 to 2,000 g/m² in weight per unit area.

8. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein a carpet original fabric in which piles 200 to 4,000 g/m² in weight per unit area is implanted in an upper surface of a base fabric 50 to 200 g/m² in weight per unit area is used as the surface skin material.

9. The method of manufacturing an automobile floor carpet as recited in claim 1, wherein a needle-punched nonwoven fabric 50 to 1,000 g/m² in weight per unit area is used as the surface skin material.

10. An automobile floor carpet having an air-flow resistance of 600 to 12,450 N·

s·

m<sup>−

3</sup> manufactured by the method as recited in claim 1.

11. A method of manufacturing an automobile floor carpet, comprising the step of:

pressing a nonwoven fabric, an adhesive film obtained immediately after extruding thermoplastic resin having melt viscosity of 5,000 to 30,000 mPa·

s at an extrusion temperature from an extruder, and a surface skin material piled together in this order with a pair of rollers.

12. The method of manufacturing an automobile floor carpet as recited in claim 11, wherein the adhesive film is 50 to 500 g/m² in weight per unit area.

13. The method of manufacturing an automobile floor carpet as recited in claim 11, wherein the nonwoven fabric is 0.1 to 30 decitex in fineness of constituent fiber and 50 to 2,000 g/m² in weight per unit area.

14. The method of manufacturing an automobile floor carpet as recited in claim 11, wherein a carpet original fabric in which piles 200 to 4,000 g/m² in weight per unit area is implanted in an upper surface of a base fabric 50 to 200 g/m² in weight per unit area is used as the surface skin material.

15. The method of manufacturing an automobile floor carpet as recited in claim 11, wherein a needle-punched nonwoven fabric 50 to 1,000 g/m² in weight per unit area is used as the surface skin material.

16. An automobile floor carpet having an air-flow resistance of 600 to 12,450 N·

s·

m<sup>−

3</sup> manufactured by the method as recited in claim 11.