JPH07229053A - Formed carpet - Google Patents

Abstract

PURPOSE:To obtain a formed carpet for laying on automobile floor, having good appearance by changing denier of a pile system and/or filament numbers depending on positions. CONSTITUTION:A polypropylene fiber 11D having high denier and high filament numbers of 1400de/96f is prepared for zone E as a pile yarn 11B and a polypropylene fiber 11D having ordinary denier and ordinary filament number of 1050de/54f is prepared for zone F and these two kinds of polypropylene fibers 11D are selectively tufted on a base fabric 11A using a tuft machine so that the zone E corresponds to a backbone part and side seal part on automobile floor and the zone F corresponds to a dash part, cloth member part, the rear terminal side seal part, etc., which do not expose on the outside to form a pile 11B. Then, a packing layer 11C is formed on the back face of the base fabric 11A and further, forming felt and sound and heat insulating felt are lined on the packing layer 11C and then, formed into a prescribed shape to provide the objective formed carpet not coarsening even if the zone E is drawn largely than the zone F and not also lowering the bulkiness.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a shaped carpet such as a carpet for automobile flooring.

[0002]

2. Description of the Related Art For example, as shown in FIG. 6, an automobile floor covering carpet (1) has a backbone portion in accordance with an automobile floor shape.
(2), cross member part (3), dash part (4), side sill (5), etc. are formed. Carpet like this
(1) is a base cloth (1A) and the base cloth (1A) as shown in FIG. 7, for example.
Made of tufted pile (1B), and a backing layer (1C), which is a synthetic resin layer for molding, is lined with a moldable felt layer (6) mixed with thermoplastic fibers. The felt layer (6) is lined with a sound-insulating heat-insulating felt (7), and the carpet (1) is molded into the shape shown in FIG. 6 through the backing layer (1C) and the moldable felt layer (6). It is laid on the floor (8).

[0003]

However, the above-mentioned conventional carpet (1) has a pile (1B) of the same denier and the same number of filaments as the whole fabric, and the same number of piles (1B) per unit length is used as a tuft. Therefore, for example, the structure where the stretch ratio becomes large during molding (Figs. 7A and 7B) has a rougher structure than the other places, and the coarse and dense structure of the carpet (1) makes the carpet appearance remarkably. It was a cause of damage. Further, since the dash portion and the seat installation portion are not exposed to the outside in a carpet for automobile flooring, the quality of the carpet becomes excessive in such a portion, which is not desirable from the viewpoint of high cost and resource saving.

[0004]

As a means for solving the above-mentioned conventional problems, the present invention is a main body of a tufted carpet provided with piles (11B) by tufting tuft yarns on a base cloth (11A). And a synthetic resin layer (11C) for molding formed on the back surface of the main body, the denier and / or the number of filaments of the pile being changed depending on the location.

Examples of materials for the base cloth and pile of the carpet body include polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, pulp, Cotton, wool,
There are synthetic fibers such as coconut fibers or natural fibers.

[0006]

In the carpet (11) of the present invention, for example, the pile (11B) at the place exposed to the outside and where the stretch ratio increases during molding has a higher denier and / or higher denier than other places.
Or use a high filament count. In this way, if the pile (11B) at the above location E is made to have a high denier and / or a high number of filaments, the above location E is stretched more than other locations F during molding of the carpet (11), and the structure becomes rough. Therefore, even if the bulkiness decreases, there is almost no change in appearance.

[0007]

EXAMPLES The present invention will be described with reference to one example shown in FIGS. 1 to 3. The carpet (11) comprises a base cloth (11A) and a base cloth (1A).
1A) is a tufted pile (11B), and the base cloth (11A) and the pile (11B) are both made of polypropylene fiber and are formed of a synthetic resin layer such as a polyethylene sheet or an acrylic resin layer. Some backing layers
(11C) is formed.

The carpet (11) is composed of two zones, a high denier and high filament number zone E and a normal denier and normal filament number zone F. In the zone E, the pile (11B) has a high denier of 1400d / 96f. High filament count polypropylene fiber
(11D) is used, and in the zone F, polypropylene fiber (11E) having a normal denier and a normal filament number of 1050d / 54f is used as the pile (11B). Therefore, the carpet (11) is formed by horizontally arranging zones E, F, E, F, E as shown in FIG. 2 to form a floor covering carpet (11) as shown in FIG.
On the back of (11), backing layer (11C) is used to line formable felt (16), and to formable felt (16) is lined with sound insulation and heat insulating felt (17), and on the floor (18) of the automobile. Lay in In the carpet (11), as shown in FIG. 3, the zone E where the polypropylene fiber (11D) as the pile (11B) having a high denier and a high number of filaments exists is in the backbone portion (2) and the side sill (5) having a large draw ratio. ).

4 and 5 show another embodiment of the present invention. In the case of this embodiment, the zones F, E, F, E, F of the carpet (21) are arranged vertically as shown in FIG. If such a carpet (21) is molded, as shown in FIG. 5, the dash part (4) not exposed to the outside, the cross member part (3) (seat installation place), the side sill part of the rear terminal
(5) A normal denier and normal filament number zone F is arranged at the (sheet installation place), and a high denier and high filament number zone E is arranged at the place exposed to the outside.

Other than the above embodiment, zone E may have a high denier and a normal filament number, or a normal denier and a high filament number.

[0011]

Therefore, according to the present invention, there is provided a molded carpet having an extremely excellent appearance and at a low cost.

[Brief description of drawings]

 1 to 3 show an embodiment of the present invention.

[Fig. 1] Cross-sectional view of carpet part

[Figure 2] Plan view of carpet

FIG. 3 is a partial sectional view of a molded carpet. FIGS. 4 and 5 show another embodiment of the present invention.

[Fig. 4] Plan view of carpet

[Figure 5] Vertical sectional view of molded carpet

FIG. 6 is a perspective view of a molded carpet.

FIG. 7 is a partial sectional view of a conventional molded carpet.

[Explanation of symbols]

 11,21 Carpet 11A Base cloth 11B Pile 11C Backing layer (molding synthetic resin layer)

Claims (1)

[Claims] 1. A main body which is a tufted carpet provided with piles by tufting tuft yarns on a base cloth,
A molded carpet comprising a molding synthetic resin layer formed on the back surface of the main body, wherein the denier and / or the number of filaments of the pile is changed depending on the location.