JP2622086B2 - Fiber laminate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber laminate, and more particularly, to a modified fiber laminate laid on a floor such as a trunk room of an automobile.

[0002]

2. Description of the Related Art Trunk mats made of a fiber laminate are laid on the floor of a trunk room of an automobile.
As shown in FIG. 3, the trunk mat (A) is laid on the floor (4) to absorb and block sound and vibration transmitted from the engine and tires.

As shown in FIG. 3, the trunk mat (A) has a skin layer (1) forming a surface layer and a skin layer (1).
And a vibration damping / sound absorbing layer (3).

[0004] The skin layer (1) comprises a cut pile or loop pile tuft carpet, or a fiber web needle punch carpet (1a), and a latex layer for stabilizing the dimensions formed on the back surface thereof. (1b).

The sound insulation layer (2) is formed by extruding a resin as shown in FIG. 3 or by a resin layer (2a) formed by a calender, or as shown in FIG. And a relatively hard and heavy weight layer (2b) obtained by impregnating a resin into a fiber web disposed below the resin layer (2a).

The vibration-damping / sound-absorbing layer (3) is a felt layer having a density of 0.05 to 0.08 g / cm ³ , which is obtained by unstacking used clothes or the like into fibers by needle punching or the like, or polyester. 100-70% of fiber and anti-hair and low-melting fiber 0-30% are mixed and density is 0.01-0.05g
/ Cm ³ felt layer is commonly used.

In addition to the above felt layer, there is a foamed urethane layer obtained by foaming a urethane resin as a vibration damping / sound absorbing layer, but the present invention is applied to a vibration damping / sound absorbing layer using felt.

When the vibration-damping and sound-absorbing layer (3) is laid on the floor (4), the vibration-damping and sound-absorbing layer functions as a member for intercepting and absorbing vibration and sound transmitted from the engine and tires, thereby suppressing the propagation of vibration and sound into the vehicle. doing.

[0009]

The propagation of vibration and sound into the vehicle interior is interrupted by the installation of the vibration damping / sound absorbing layer (3), but the lower surface of the vibration damping / sound absorbing layer (3) is the floor (4). Since the vibration-absorbing and sound-absorbing layer (3) is made of a felt having a relatively gently entangled structure other than urethane foam, as shown in FIG. The frictional force acting between (4) and the felt layer (3) causes the two to rub each other, and the rubbing causes fluff fraying (3A) on the lower surface.

The fluff fray (3A) grows with the passage of time, as shown in FIG. 5B, and greatly reduces the beauty of the back surface of the trunk mat (A).

[0011] The trunk mat is often peeled off from the floor at the time of tire replacement or the like, and the occurrence of fluff fraying on the back of the trunk mat is not preferable.

In order to eliminate fuzziness by forming the vibration damping / sound absorbing layer (3) having a single-layer structure shown in FIGS. 3 and 4 with felt, the content of the low-melting fiber may be increased. However, due to the hardening of the vibration damping / sound absorbing layer (3), the spring constant increases, and the vibration damping effect is impaired.

[0013]

As a means for solving the above problems, the present invention provides a sound insulation layer comprising a resin layer or a resin impregnated fiber layer on the lower surface of a skin layer (1) made of a fibrous material. (2) Vibration damping and sound absorbing layer made of felt (3)
Are sequentially laminated,

A vibration-damping and sound-absorbing layer made of the felt (3)
On the lower side, a fuzz fraying prevention layer (4) having a thickness of 50% or less of the total thickness of the vibration damping / sound absorbing layer (3) and containing at least 30 parts by weight of a polyester or polyolefin low melting point fiber is disposed. A fiber laminate is provided.

[0015]

[Function] When the floor mat is laid on the floor, the fluff fray prevention layer formed on the lower surface of the vibration damping / sound absorbing layer is in direct contact with the floor, and therefore, even if the floor mat is rubbed, the fluff is applied to the back of the floor mat. No fraying occurs. The weight of the fluff fraying prevention layer is 10 to 1
Since it is as small as 50 g, the vibration damping and sound absorbing properties of the felt layer can be maintained at a predetermined level.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A specific example of the present invention will be described with reference to FIGS. In the following description, the same components as those in FIGS. 3 and 4 showing the prior art are denoted by the same reference numerals, and the description of the same items will not be repeated.

The fiber laminate shown in FIG. 1, for example, the trunk mat (A) has a regular polyester (T
g: 70 ° C., Mp: 260 ° C.) and a skin layer (1) made of staples and a resin layer (2a), or as shown in FIG. 2, by impregnation and heating of the resin layer (2a) and the resin. A sound insulation layer (2) composed of a cured weight layer (2b) is laminated and arranged, and below the sound insulation layer (2), 80 parts by weight of the regular polyester fiber and a low melting polyester fiber (Tg: 70). (C, softening point 110 ° C to 200 ° C) A vibration damping / sound absorbing layer (3) composed of a mixed web with 20 parts by weight is provided. The thickness of the vibration-damping and sound-absorbing layer (3) is about 10 mm under no load, the web forming condition and the needling process condition, and the low melting point so that the fiber lamination density is 0.04 g / cm ^3. Conditions for dissolving the fibers are selected.

The total thickness of the vibration-damping / sound absorbing layer (3) and the fuzz fraying-preventing layer (5) described later has a lower content of the low-melting fiber than the fuzz-fraying preventing layer (5). (3) is adjusted so as to have a thickness dimension of 50% or more.

On the lower side of the vibration-damping / sound absorbing layer (3), a mixed web of 60 parts by weight of regular polyester fiber and 40 parts by weight of low-melting polyester fiber has a thickness of about 0.5 mm under no load. Size and about 80g
A fluff fray prevention layer (5) having a basis weight of / m ² is provided.

The amount of the low melting point fiber to be incorporated in the fluff fray prevention layer (5) is adjusted so as to occupy at least 30 parts by weight of the total weight of the fibers constituting the fuzz fray prevention layer (5). , More is preferable. The weight per unit area of the constituent fibers of the fluff fray prevention layer (5), that is, the basis weight, can be controlled by adjusting the web forming conditions to 10-1.
Adjust so as to fall within the range of 50 g / m ² .

The fluff fraying prevention layer (5) and the felt layer (3) for vibration suppression and sound absorption are formed into an integral structure by needle punching.

The present invention does not require the sound absorbing and sound insulating functions as shown in FIG. 6, and can be applied to a trunk mat (B) intended only for a cushion function.

The trunk mat (B) shown in FIG. 6 has a low mixing ratio of low melting point fibers of 200 to 900 g under the skin layer (1) in order to effectively exhibit cushioning properties.
/ M ^{2 in} which a thick felt layer (3) is laminated, or in order to obtain an inexpensive trunk mat (B), the mixing ratio of expensive low-melting fiber is reduced to 200 to 90.
A felt layer (3) having a large thickness of 0 g / m ² is laminated. In addition, the entangled structure of the fibers is adjusted by mixing the low melting point fibers. That is, when the mixing ratio is large, the cushion function is reduced, and when the mixing ratio is small, the cushion function is increased. However, when the mixing ratio is too small, the cushion function is reduced with time.

In the case of the above-mentioned trunk mat (B), fuzz is generated on the back surface of the felt layer (3) during use as described for the trunk mat (A) in FIGS. 3 and 4.

In the above trunk mat (B), FIG.
As shown by, when the fray fray prevention layer (5) is provided below the felt layer (3), the generation of fuzz frays generated on the contact surface with the floor (4) can be prevented. In addition, the fray fray prevention layer (5) on the lower surface is made of a trunk mat (B).
And the trunk mat (B) can be made rigid.

Although the present invention has been described as applied to a trunk mat, the present invention may be applied to a floor mat laid on a floor in a vehicle cabin. Creates a comfortable atmosphere in the cabin by absorbing and blocking.

[0027]

According to the present invention, 50% or more of the total thickness of the vibration damping / sound absorbing layer and the fluff fray prevention layer is left as a vibration damping / sound absorbing layer having a low mixing ratio of low melting point fibers and a small spring constant. The mixing ratio of the low-melting-point fiber is increased only in the outer fray fray prevention layer that rubs against the floor, etc., thereby reducing the fuzz on the back of the trunk mat without substantially reducing the damping effect originally possessed by the vibration damping and sound absorbing layers. It suppresses the deterioration of aesthetics.

[Brief description of the drawings]

FIG. 1 is a partial longitudinal sectional view of a fiber laminate (floor mat) illustrating a first specific example of the present invention.

FIG. 2 is a partial longitudinal sectional view of a fiber laminate (floor mat) illustrating a second specific example of the present invention.

FIG. 3 is a partial longitudinal sectional view of a conventional fiber laminate (floor mat);

FIG. 4 is a partial longitudinal sectional view of another conventional fiber laminate (floor mat).

FIG. 5A is a bottom view of a conventional vibration damping / sound absorbing layer illustrating an initial surface state attached to a vehicle body, and FIG.
Bottom view of conventional vibration-damping and sound-absorbing layer at the time when a predetermined use period has elapsed,

FIG. 6 is a partial longitudinal sectional view of another conventional fiber laminate (floor mat).

FIG. 7 is a partial longitudinal sectional view of a fiber laminate (floor mat) illustrating a third specific example of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin layer 2 Sound insulation layer 3 Vibration suppression / sound absorption layer 4 Fuzz fraying prevention layer 5 Floor A Fiber laminate

Claims (4)

(57) [Claims] A sound insulation layer comprising a resin layer or a fiber layer impregnated with a resin on a lower surface of a skin layer made of a fibrous material,
In a layer in which a damping / sound absorbing layer made of felt is sequentially laminated, a polyester-based material having a thickness of 50% or less of the total thickness of the damping / sound absorbing layer below the felt is used.
Alternatively, a fibrous laminate comprising a fuzz fraying prevention layer containing at least 30 parts by weight of a polyolefin-based low-melting fiber. 2. The fiber laminate according to claim 1, wherein the basis weight of the constituent fibers of the fluff fray prevention layer containing the low-melting fiber is set in the range of 10 to 150 g / m ² . 3. The fiber laminate according to claim 1, wherein the fluff fray prevention layer containing the low-melting fiber is integrally formed with a felt layer for vibration damping and sound absorption by needle punching. . 4. A vibration damping / sound absorbing layer made of felt is laminated on a lower surface of a skin layer made of a fibrous material, wherein the vibration damping / sound absorbing layer made of felt is provided below the vibration damping / sound absorbing layer. Polyester-based at a thickness of 50% or less of the total thickness of
Alternatively, a fibrous laminate comprising a fuzz fraying prevention layer containing at least 30 parts by weight of a polyolefin-based low-melting fiber.