Automobile floor carpet and method for manufacturing the same

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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present invention are shown by way of example, and not limitation, in the accompanying figures, in which:

FIG. 1 is a cross-sectional view showing an embodiment of an automobile floor carpet according to the present invention; and

FIG. 2 is an explanatory view showing a manufacturing method of the automobile floor carpet according to the present invention.

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−3 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−3 manufactured by the method as recited in claim 11.