Title:
VEHICLE MOUNTING CARPET AND PRODUCING METHOD THEREOF
Kind Code:
A1


Abstract:
A vehicle mounting carpet including a carpet matrix including a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth, and a back face side member constituted by a nonwoven cloth bonded to a back face side of the carpet matrix, in which a face of the back face side member brought into contact with the carpe member for the matrix is formed with a number of slender cords which can be arranged along a width direction of a vehicle body when mounted onto the carpet member for the matrix.



Inventors:
Nakagawa, Tsuneyasu (Tokyo, JP)
Application Number:
12/205360
Publication Date:
01/21/2010
Filing Date:
09/05/2008
Assignee:
DAISHIN INDUSTRIES CO., LTD. (Tokyo, JP)
Primary Class:
Other Classes:
156/72
International Classes:
D05C17/02; D05C15/04
View Patent Images:



Primary Examiner:
JUSKA, CHERYL ANN
Attorney, Agent or Firm:
ARENT FOX LLP (1050 CONNECTICUT AVENUE, N.W., SUITE 400, WASHINGTON, DC, 20036, US)
Claims:
What is claimed is:

1. A vehicle mounting carpet including: a carpet matrix comprising a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth; and a back face side member comprising a nonwoven cloth mounted to a back face side of the carpet matrix; wherein a face of the back face side member brought into contact with the carpet member for the matrix is formed with a number of slender cords capable of being arranged along a width direction of a vehicle body when the back face side member is mounted on the carpet member for the matrix.

2. The vehicle mounting carpet according to claim 1, wherein the back face side member comprises a base cloth bonded to the carpet matrix side base cloth and a needle punch working portion comprising a nonwoven cloth bonded to a back face side of the base cloth and brought into contact with the carpet member for the matrix; wherein the slender cord is formed by piercing a plurality of needle punch needles and the plurality of needle punch needles are provided with a plurality of needle rows arranged along a direction of carrying the nonwoven cloth in a direction orthogonal to the carrying direction; and wherein the needle rows contiguous to each other are provided to be shifted from each other in the carrying direction by an amount of an interval dimension of a half of an interval dimension of a pair of the needles along the carrying direction.

3. The vehicle mounting carpet according to claim 1, wherein the slender cord is formed by projecting densely gathered ring-like fibers.

4. The vehicle mounting carpet according to claim 3, wherein the slender cords are formed by being spaced apart from each other by an interval dimension of a half of an interval dimension of two of the needle punch needles at immediate vicinities in the needle row along the carrying direction of the nonwoven cloth.

5. The vehicle mounting carpet according to claim 4, wherein the interval dimension is 5 mm.

6. The vehicle mounting carpet according to claim 1, wherein the nonwoven cloth is a felt member.

7. The vehicle mounting carpet according to claim 1, wherein a thermoplastic resin is impregnated to a face of the back face side member brought into contact with the carpet member for the matrix.

8. The vehicle mounting carpet according to claim 6, wherein the thermoplastic resin is an acrylic species resin.

9. The vehicle mounting carpet according to claim 7, wherein the thermoplastic resin is sprayed to the back face side member by a spray.

10. A method of fabricating a vehicle mounting carpet, the vehicle mounting carpet including: a carpet matrix comprising a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth; and a back face side member comprising a nonwoven cloth bonded to a back face side of the carpet matrix; wherein the back face side member is formed by needle punch working, the method comprising: a first piercing step of piercing needle punch needles successively to the nonwoven cloth carried at predetermined dimensions by a needle punch working apparatus provided with a plurality of rows of needle rows provided along a direction of carrying the nonwoven cloth along a direction orthogonal to the carrying direction and including a number of the needle punch needles arranged with the needles by being shifted in the carrying direction by an amount of a distance dimension of a half of a needle interval dimension along the carrying direction in the rows contiguous to each other; and, thereafter, a second piercing step of forming a slender cord in the direction orthogonal to the carrying direction by carrying the nonwoven cloth by the amount of the distance dimension of the half of the interval dimension in the carrying direction of the needles of the contiguous needles of the respective rows of the needles pierced in the first piercing step, and thereafter forming a new needle punch portion contiguous to the needle punch portion pierced in the first piercing step by piercing the needle punch needles.

11. A method of fabricating a vehicle mounting carpet; further comprising: a back face side member forming step of bonding a back face side of a base cloth to a side face portion of the needle punch working portion opposed to the slender cord in a thickness direction after forming the slender cord at the needle punch working portion by the first piercing step, and the second piercing step; and a carpet matrix bonding step of bonding the carpet matrix side base cloth to a surface of the base cloth of the back face side member formed at the back face side member forming step.

12. The method of fabricating a vehicle mounting carpet according to claim 10, wherein the distance dimension of the half of the interval dimension in the carrying direction of the needles contiguous to each other is 5 mm.

13. The method of fabricating a vehicle mounting carpet according to claim 10, further comprising: a thermoplastic resin spraying step of spraying the thermoplastic resin to the back face side member by a spray after the carpet matrix bonding step; and a drying step of drying the sprayed thermoplastic resin.

Description:

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a vehicle mounting carpet mounted on a floor face at inside of a vehicle compartment of an automobile, particularly relates to a vehicle mounting carpet including a back face side member comprising needle punch nonwoven cloth.

Generally, a floor face at inside of a vehicle compartment of an automobile is arranged with a predetermined sound absorbing member on a floor panel, and a top face side of the sound absorbing member is laid with a carpet member for a matrix referred to as a so-to-speak line mat.

A top face side of the carpet member for the matrix is laid with a vehicle mounting carpet referred to as a so-to-speak option mat with an object of promoting an outlook quality at inside of a vehicle chamber, generally, the vehicle mounting carpet is formed by bonding a predetermined back face side member to a back face of a carpet matrix of a so-to-speak tufted carpet in which piles are tufted on a base cloth.

In running an automobile, the vehicle mounting carpet undergoes a friction frequently by feet of a driver.

In this case, when the vehicle mounting carpet is slid on the carpet member for the matrix, not only the outlook quality is deteriorated but there is a concern of hampering an operation of an accelerator/brake pedal or the like by pinching the vehicle mounting carpet by the accelerator/brake pedal to pose a serious problem from a safety view point.

Therefore, according to JP-A-2002-301980, in order to prevent sliding at inside of a vehicle compartment, there is proposed a vehicle mounting carpet provided with a projected portion for slide-preventing at a back face side member of a vehicle mounting carpet.

As shown by FIG. 6, a vehicle mounting carpet 70 according to JP-A-2002-301980 is formed by laminating to integrate an elastic layer 72 comprising a thermoplastic elastomer with a lower face side of a top member 71 and arranging a number of slide-preventing projections 74 at a bottom face 73 of the elastic layer 72 in a state of being aligned longitudinally and laterally by being spaced apart from each other by intervals therebetween.

Further, the slide-preventing projection 74 is formed by projecting a hanging spike shape projection 76 on a bottom side of a base seat portion 75 constituted by a shape of a circular disk.

When the vehicle mounting carpet 70 is laid at inside of a vehicle compartment, the slide-preventing projection 76 invades inside of a pile of the carpet member for the matrix (not illustrated in FIG. 6), and the vehicle mounting carpet is prevented from sliding on the carpet member for the matrix.

However, the elastic layer 72 of the vehicle mounting carpet 70 comprises a thermoplastic elastomer, and therefore, the elastic layer 72 is not provided with a sound absorbing operation to provide a drawback that running sound or noise at inside of the vehicle is reflected by the elastic layer 72, and an effect of a sound absorbing member applied to the vehicle body is hampered.

In view of the drawback, according to JP-A-2002-4163, there is proposed a vehicle mounting carpet having both of a slide-preventing effect and a sound absorbing effect of running sound or the like.

As shown by FIG. 7, a vehicle mounting carpet 80 according to JP-A-2002-4163 mentioned above is formed by a surface member 81 and a back face member 82 pasted to one face of the surface member 81.

The back face member 82 is fabricated by projecting a fiber 83 from a back face by needle punch working, shearing the projected fiber 83 and forming a resin lump 84 larger than a diameter dimension of the fiber 83 by a heat treatment.

When the vehicle mounting carpet 80 is laid on a matrix carpet member (not illustrated in FIG. 7) at inside of a vehicle compartment, the vehicle mounting carpet 80 is prevented from being slid on the carpet member for the matrix since the resin lump 84 invades inside of a pile of the carpet member for the matrix, and since the back face member 82 is a nonwoven cloth fabricated by the needle punch working, the vehicle mounting carpet 80 does not reflect but absorbs running sound or noise at inside of the vehicle, and therefore, the effect of the absorbing member applied to the vehicle body is not hampered.

However, according to the vehicle mounting carpet 80, when the carpet member for the matrix is formed by a needle punch carpet, a surface of the carpet member for the matrix is formed by a fiber in a ring-like shape, and therefore, the rein lump 84 is easy to engage and the slide-preventing effect is considerable, however, when the carpet member for the matrix is formed by a so-to-speak tufted carpet, a surface of the carpet member for the matrix is formed by a wire-like fiber, and therefore, even when the resin lump 84 invades inside of the carpet member for the matrix, the tufted carpet does not engage with the carpet member for the matrix to provide a drawback that the slide-preventing effect is not worked.

In recent years, a case of using a tufted carpet having a higher outlook quality for a carpet member for a matrix has been increased centering on high-grade passenger vehicles.

Despite the above-described situation, a vehicle mounting carpet having an excellent slide-preventing effect even in a tufted carpet has not been supplied until present time and a request for developing such a carpet from an automobile industry field is enormous.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a vehicle mounting carpet having an excellent slide-preventing effect even when a carpet member for a matrix at inside of a vehicle compartment is a tufted carpet.

In order to resolve the problem, according to the present invention, there is provided a vehicle mounting carpet including:

a carpet matrix comprising a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth; and

a back face side member comprising a nonwoven cloth mounted to a back face side of the carpet matrix;

wherein a face of the back face side member brought into contact with the carpet member for the matrix is formed with a number of slender cords capable of being arranged along a width direction of a vehicle body when the back face side member is mounted on the carpet member for the matrix.

Therefore, by making the plurality of slender cords arranged along the width direction of the vehicle body invade inside of the pile of the carpet member for the matrix to be engaged with a pile fiber, the vehicle mounting carpet is fixed onto the carpet member for the matrix to prevent sliding in a front and rear direction of the vehicle body.

Further, according to the invention, the back face side member comprises a base cloth bonded to the carpet matrix side base cloth and a needle punch working portion comprising a nonwoven cloth bonded to a back face side of the base cloth and brought into contact with the carpet member for the matrix;

wherein the slender cord is formed by piercing a plurality of needle punch needles and the plurality of needle punch needles are provided with a plurality of needle rows arranged along a direction of carrying the nonwoven cloth in a direction orthogonal to the carrying direction; and

wherein the needle rows contiguous to each other are provided to be shifted from each other in the carrying direction by an amount of an interval dimension of a half of an interval dimension of a pair of the needles along the carrying direction.

Therefore, one face of the needle punch working portion is formed with the slender cord in the direction orthogonal to the carrying direction of the nonwoven cloth by piercing the needle punch needle.

The slender cord is formed by densely gathering a number of fibers raked out by piercing the needle punch needle from inside of the nonwoven cloth forming the needle punch working portion.

Therefore, when the vehicle mounting carpet having the needle punch working portion is mounted on the carpet member for the matrix comprising the tufted carpet by directing the cord portion to the bottom side, the fibers forming the slender cord invade inside of the pile of the carpet member for the matrix. Not only the wire-like fibers of the piles of the carpet member for the matrix and the fibers of the slender cords entangled with each other, but also the slender cords per se constitute a sliding stopper in the front and rear direction of the vehicle body to prevent sliding. Therefore, sliding of the vehicle mounting carpet relative to the front and rear direction of the vehicle body on the carpet member for the matrix is prevented.

Further, according to the present invention, the slender cord is formed by projecting densely gathered ring-like fibers.

Therefore, when the vehicle mounting carpet having the needle punch working portion at the back face side member is mounted onto the carpet member for the matrix comprising the tufted carpet by directing the cord portion to the bottom side, the ring-like fibers forming the slender cords invade inside of the pile of the carpet member of the matrix, tip portions of the wire-like fibers of the pile of the carpet member for the matrix engage with rings of the ring-like fibers. The vehicle mounting carpet is fixed onto the carpet member for the matrix by a principle of a so-to-speak face fastener to prevent sliding in the front and rear direction of the vehicle body.

Further, according to the present invention, the slender cords are formed by being spaced apart from each other by an interval dimension of a half of an interval dimension of two of the needle punch needles at immediate vicinities in the needle row along the carrying direction of the nonwoven cloth.

Further, according to the invention, the interval dimension is 5 mm.

Further, a number of slender cords are formed along the width direction of the vehicle body at respective 5 mm intervals to prevent sliding in the front and rear direction of the vehicle body.

Further, according to the present invention, the nonwoven cloth is a felt member.

Further, according to the invention, a thermoplastic resin is impregnated to a face of the back face side member brought into contact with the carpet member for the matrix.

According to the present invention, the thermoplastic resin is an acrylic species resin.

Therefore, by a viscosity provided to the thermoplastic resin, the vehicle mounting carpet is mounted on the carpet member for the matrix in the densely gathered state.

Further, according to the present invention, the thermoplastic resin is sprayed to the back face side member by a spray.

Therefore, the thermoplastic resin is uniformly impregnated to the face of the back face side member brought into contact with the carpet member for the matrix.

Further, according to the invention, there is provided a method of fabricating a vehicle mounting carpet, the vehicle mounting carpet including:

a carpet matrix comprising a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth; and

a back face side member comprising a nonwoven cloth bonded to a back face side of the carpet matrix;

wherein the back face side member is formed by needle punch working, the method comprising:

a first piercing step of piercing needle punch needles successively to the nonwoven cloth carried at predetermined dimensions by a needle punch working apparatus provided with a plurality of rows of needle rows provided along a direction of carrying the nonwoven cloth along a direction orthogonal to the carrying direction and including a number of the needle punch needles arranged with the needles by being shifted in the carrying direction by an amount of a distance dimension of a half of a needle interval dimension along the carrying direction in the rows contiguous to each other; and, thereafter,

a second piercing step of forming a slender cord in the direction orthogonal to the carrying direction by carrying the nonwoven cloth by the amount of the distance dimension of the half of the interval dimension in the carrying direction of the needles of the contiguous needles of the respective rows of the needles pierced in the first piercing step, and thereafter forming a new needle punch portion contiguous to the needle punch portion pierced in the first piercing step by piercing the needle punch needles.

Therefore, one face of the needle punch working portion is formed with the slender cords in the direction orthogonal to the carrying direction by aligning the needle punch portion formed by the first piercing step and the second piercing step along the direction orthogonal to the carrying direction.

Further, according to the invention, the method of fabricating a vehicle mounting carpet further comprising:

a back face side member forming step of bonding a back face side of a base cloth to a side face portion of the needle punch working portion opposed to the slender cord in a thickness direction after forming the slender cord at the needle punch working portion by the first piercing step, and the second piercing step; and

a carpet matrix bonding step of bonding the carpet matrix side base cloth to a surface of the base cloth of the back face side member formed at the back face side member forming step.

Therefore, there is provided the vehicle mounting carpet including the back face side member having the plurality of slender cords in the direction orthogonal to the carrying direction at the needle punch working portion formed by the above-described steps.

Further, according to the present invention, the method further comprises, the distance dimension of the half of the interval dimension in the carrying direction of the needles contiguous to each other is 5 mm.

Therefore, the interval dimension of the respective slender cords formed at the needle punch working portion becomes 5 mm.

Further, according to the invention, the method further comprises a thermoplastic resin spraying step of spraying the thermoplastic resin to the back face side member by a spray after the carpet matrix bonding step; and

a drying step of drying the sprayed thermoplastic resin.

Therefore, the thermoplastic resin is uniformly impregnated to inside of the back face side member.

According to the invention, there can be provided the vehicle mounting carpet having an excellent slide-preventing effect even when the carpet member for the matrix is the tufted carpet by making the fibers of the surface of the slender cord invade to be engaged with inside of the pile of the carpet member for the matrix by forming the number of slender cords which can be arranged along the width direction of the vehicle body when the face of the back face side member of the vehicle mounting carpet brought into contact with the carpet for the matrix is mounted onto the carpet member for the matrix.

Further, even when a force in the front and rear direction of the vehicle body is exerted to the vehicle mounting carpet, by arranging the plurality of slender cords along the width direction of the vehicle body, sliding of the vehicle mounting carpet in the front and rear direction of the vehicle body can effectively be prevented.

Particularly, according to the invention, the slender cord is formed by projecting the densely gathered ring-like fibers. Therefore, even when the carpet member for the matrix is a so-to-speak tufted carpet, the wire-like fibers of the pile of the carpet member for the matrix are entangled to engage with the ring-like fibers. By the principle of the so-to-speak face fastener, sliding of the vehicle mounting carpet on the carpet member for the matrix is further solidly prevented.

Further, according to the invention, the nonwoven cloth of the rear face side member is formed by the felt member, and therefore, noise generated by a vibration in running or the like is efficiently absorbed. Therefore, there can be provided the vehicle mounting carpet capable of achieving the higher sound absorbing effect.

Further, according to the invention, the face of the back face side member brought into contact with the carpet member for the matrix is impregnated with the thermoplastic resin constituting the acrylic species resin. Therefore, by the viscosity provided to the thermoplastic resin, the vehicle mounting carpet is further solidly fixed onto the carpet member for the matrix, there can be provided the vehicle mounting carpet capable of further effectively preventing sliding of the vehicle mounting carpet.

Particularly, according to the invention, the thermoplastic resin is sprayed to the back face side member by the spray. Therefore, the thermoplastic resin is further uniformly impregnated and also the slide-preventing effect becomes uniform over an entire region of the back face side member.

Further, according to the invention, there are provided the first piercing step of piercing the needle punch needles successively to the nonwoven cloth carried at the predetermined dimension by the needle punch working apparatus provided with the plurality of rows of needle rows provided along the carrying direction of the nonwoven cloth along the direction orthogonal to the carrying direction and including a number of the needle punch needles arranged to be shifted in the carrying direction by the amount of the distance dimension of the half of the needle interval dimension along the carrying direction in the rows contiguous to each other, thereafter, the second piercing step of forming the slender cords in the direction orthogonal to the carrying direction by forming a new needle punch portion contiguous to the needle punch portion pierced at the first piercing step by carrying the nonwoven cloth by the amount of the distance dimension of the half of the interval dimension in the carrying direction of the needles contiguous to each other of the respective rows of the needles pierced at the first piercing step. Therefore, by adjusting the dimension of the needle punch working portion carried during the one time piercing operation to be the half of the interval dimension of the needle punch needles contiguous to each other in the same needle row in the carrying direction, the slender cord shape in the direction orthogonal to the carrying direction can easily be formed at the needle punch working portion without reforming a general needle punch working apparatus.

Further, according to the invention, there can easily be provided the vehicle mounting carpet having the number of slender cords arranged along the width direction of the vehicle body at the face of the back face side member brought into contact with the carpet member for the matrix by providing the back face side member forming step of bonding the back face of the base cloth to the side face portion of the needle punch working portion opposed to the slender cord in the thickness direction, and the carpet matrix bonding step of bonding the carpet matrix side base cloth to the surface of the base cloth of the back face side member formed at the surface side member forming step after the second piercing step.

Further, according to the invention, by the viscosity provided to the thermoplastic resin sprayed to the back face side member, the face of the back face side member brought into contact with the carpet member for the matrix is adhered to be fixed to the carpet member for the matrix, and therefore, the vehicle mounting carpet which is made to be further difficult to slide on the carpet for the matrix can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a carpet according to an embodiment showing an embodiment of a vehicle mounting carpet according to the invention;

FIG. 2 illustrates a sectional view of a state of mounting the vehicle mounting carpet according to the embodiment on a carpet member for a matrix and a sectional view enlarging a portion of bringing a slender cord and the carpet member for the matrix into contact with each other showing the embodiment of the vehicle mounting carpet according to the invention;

FIG. 3 illustrates a side view and a plane view conceptually showing an alignment of a needle punch needle according to the embodiment showing an embodiment of a method of fabricating a vehicle mounting carpet according to the invention;

FIG. 4 is a plane view of a needle punch working apparatus showing a first piercing step and a second piercing step according to an embodiment showing the embodiment of the method of fabricating the vehicle mounting carpet according to the invention;

FIG. 5 is a flowchart showing the embodiment of the method of fabricating the vehicle mounting carpet according to the invention; and

FIG. 6 and FIG. 7 are sectional views of carpets of related arts.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the invention will be explained in reference to the drawings by taking an example of a case in which a needle punch working portion of a back face side member is formed by a felt member and a thermoplastic resin impregnated to the back face side member is acrylic species resin.

(1) Vehicle Mounting Carpet

As shown by FIG. 1, a vehicle mounting carpet 10 according to the embodiment includes a carpet matrix 14 comprising a carpet matrix side base cloth 12 mounted above a carpet member 11 for a matrix laid on a floor panel of an automobile, and a pile 13 implanted from a surface side of the carpet matrix side base cloth 12, and a back face side member 15 comprising a nonwoven cloth constituting a felt member bounded to a back face side of the carpet matrix 14.

As shown by FIG. 2, a face 16 of the back face side member 15 brought into contact with the carpet member 11 for the matrix is formed with a number of slender cords 17 which can be arranged along a width direction of a vehicle body (that is, a direction orthogonal to a paper face of FIG. 2) when mounted above the carpet member 11 for the matrix.

The back face side member 15 comprises a base cloth 19 bonded to the carpet matrix side base cloth 12, and a needle punch working portion 20 bounded to a back ace side of the base cloth 19 and comprising a nonwoven cloth brought into contact with the carpet member 11 for the matrix, as shown by FIG. 3, the slender cord 17 is formed by piercing a plurality of needles 21 for the needle punch to the nonwoven cloth 20.

The plurality of needle punch needles 21 are provided with needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, 22m along a direction orthogonal to a carrying direction and the needle rows contiguous to each other (for example, 22a and 22b) are provided to shift from each other in the carrying direction by an amount of an interval dimension Q formed to be 5 mm of a half of an interval dimension P of a pair of needles along the carrying direction formed to be 10 mm. Further, as shown by FIG. 2, densely gathered ring-like fibers 23 are projected to form the slender cord 17.

Further, as shown by FIG. 1 and FIG. 3, the slender cords 17 are formed by being spaced apart from each other by the interval dimension Q of the half of the interval dimension P of the two needle punch needles 21 (not illustrated in FIG. 2) at immediate vicinities in the needle rows along the carrying direction of the nonwoven cloth 20. Further, as shown by FIG. 2, the contact face 16 of the back face side member 15 with the carpet member 11 for the matrix is impregnated with a thermoplastic resin 24 constituting an acrylic species resin by spraying.

(2) Method of Fabricating Vehicle Mounting Carpet

As shown by FIG. 3, a method of fabricating the vehicle mounting carpet 10 according to the embodiment includes a first piercing step 26 of piercing the needle punch needles 21 to the nonwoven cloth 20 carried by being spaced apart from each other by the predetermined dimension Q successively as shown by FIG. 4 by a needle punch working apparatus 25 including a number of the needle punch needles 21 in which the needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, 22m provided along the carrying direction A of the nonwoven cloth 20 are provided along the direction orthogonal to the carrying direction A, in the needle rows contiguous to each other (for example, 22a and 22b), the needles 21 constituting the needle rows (for example, 22a and 22b) are arranged to be shifted from each other in the carrying direction A by the amount of the predetermined dimension Q formed by 5 mm of the half of the needle interval dimension P along the carrying direction A formed to be 10 mm, thereafter, a second piercing step 27 of forming the slender cords 17 in the direction orthogonal to the carrying direction A by carrying the nonwoven cloth 20 by the amount of the distance dimension Q of the half of the interval dimension P in the carrying direction A of the needles 21 contiguous to each other in the respective rows of the needles 21 pierced in the first piercing step 26 and thereafter forming a new needle punch portion 28b contiguous to a needle punch portion 28a pierced in the first piercing step 26 by piercing the needle punch needle 21.

Further, after forming the slender cords 17 at the needle punch working portion 20 by the first piercing step 26 and the second piercing step 27, as shown by FIG. 5, the method includes a back face side member forming step 30 of bonding the back face of the base cloth 19 to a counter slender cord side face portion 29 in a thickness direction of the needle punch working portion 20, and a carpet matrix bonding step 31 of bonding the carpet matrix side base cloth 12 to the surface of the base cloth 19 of the back face side member 15 formed by the back face side member forming step 30.

Further, as shown by FIG. 5, the method further includes a thermoplastic resin spraying step 32 of spraying the thermoplastic resin 24 constituting the acrylic resin to the back face side member 15 after the carpet matrix bonding step 31 by a spray (not illustrated) and a drying step 33 of drying the sprayed thermoplastic resin 24.

EXAMPLES

Examples of the vehicle mounting carpet by the constitution of the above-described embodiment will be described in details in reference to the drawings. FIG. 1 is a sectional view of the vehicle mounting carpet 10 by the constitution of the example.

The vehicle mounting carpet 10 is formed by bringing the carpet matrix 14 and the back side member 15 into press contact with each other to bond by means of thermal welding or the like.

The carpet matrix 14 is a so-to-speak tufted carpet formed by tufting the pile 13 to the carpet matrix side base cloth 12.

Further, the back face side member 15 is formed by bringing the base cloth 19 into press contact to bond with the surface portion of the needle punch working portion 20 formed by the nonwoven cloth comprising the felt member, the back face side member 15 and the carpet matrix 14 are brought into press contact to fix by way of an adhering agent to constitute the vehicle mounting carpet 10.

Further, FIG. 2 illustrates a sectional view in a state of mounting the vehicle mounting carpet 10 on the carpet member 11 for the matrix constituting the tufted carpet laid on a floor panel 18 and a sectional view enlarging a portion of the slender cord 17 of the back face side member 15 of the vehicle mounting carpet 10 bonded with a pile 36 of the carpet member 11 for the matrix.

The carpet member for the matrix is formed by tufting the pile 36 formed by densely gathering wire-like fibers 35 to a base cloth 34.

When the vehicle mounting carpet 10 is mounted on the carpet matrix 11 for the matrix, the slender cord 17 is arranged in a direction orthogonal to a front and rear direction of the vehicle body indicated by an arrow mark B. Therefore, the slender cord 17 is brought into press contact with the pile 36 of the carpet member 11 of the matrix. By a friction force by invasion into the pile 36, and an adhering force produced by entangling the wire-like fibers 35 constituting the pile 36 of the carpet member 11 for the matrix with the densely gathering ring-like fiber 23 constituting the slender cord 17 to engage therewith by a principle of a so-to-speak face fastener, the vehicle mounting carpet 10 is solidly fixed onto the carpet member 11 for the matrix. Therefore, even when the carpet member 11 for the matrix is formed by a so-to-speak tufted carpet, the vehicle mounting carpet 10 can effectively be prevented from being slid.

As shown by FIG. 1, the needle punch working portion 20 is impregnated with the thermoplastic resin 24 constituting the acrylic species resin. Therefore, by an adhering operation by a viscosity provided to the thermoplastic resin 24, the vehicle mounting carpet 10 and the carpet member 11 for the matrix are further solidly bonded and a slide-preventing effect can further be promoted.

An example of a method of fabricating a vehicle mounting carpet by the constitution of the example will be described in details in reference to the drawings.

FIG. 3 conceptually shows a side view and a plane view of the needle punch working apparatus 25 for forming the slender cord 17 at the needle punch working portion 20 of the back face side member 15 of the vehicle mounting carpet 10.

The needle punch working apparatus 25 is formed by arranging the plurality of needle punch needles 21 at the base seat portion 37 in a shape of a rectangular plate having a predetermined length.

The needle punch needles 21 form the needle rows 22a, 22b, 22c, 22d, 22e, 22f, 22g, 22h, 22i, 22j, 22k, 22L, 22m arranged along the carrying direction and the needle rows 22a through 22m are arranged in the direction orthogonal to the carrying direction.

The needle punch needles 21 are arranged to be spaced apart from each other respectively by 10 mm (interval dimension P) in the same row.

Further, the needle punch needles 21 are arranged by being shifted by 5 mm (distance dimension Q) in the carrying direction between the contiguous rows.

FIG. 4 is a plane view for explaining an operation of the needle punch working apparatus 25 in the first piercing step 26 and the second piercing step 27 of the method of fabricating the vehicle mounting carpet 10.

An upper stage portion of FIG. 4 shows an operation of the needle punch working apparatus 25 in the first piercing step 26, and a lower stage thereof shows the operation of the needle punch working apparatus 25 in the second piercing step 27, respectively.

As shown by the upper stage of FIG. 4, at a time point of carrying the needle punch working portion 20 comprising the nonwoven cloth formed in a strip-like shape by a predetermined length on the needle punch working apparatus 25, at the first piercing step 26, the needle punch working portion 20 is pierced by the needle punch needles 21, and a needle punch portion 28a is formed by the needle punch needles 21 disposed at the same positions in the carrying direction of the needle rows 22b, 22d, 22f, 22h, 22j, 22L.

Thereafter, as shown by the lower stage of FIG. 4, at the second piercing step 27, the needle punch working portion 20 formed in the strip-like shape is carried by the distance dimension Q (5 mm) along the carrying direction, and the needle punch working portion 20 is pierced by the needle punch needles 21 again.

At this occasion, by the needle punch needles 21 disposed at the same positions in the carrying direction of the needle rows 22a, 22c, 22e, 22g, 22i, 22k, 22m, the needle punch portion 28b is formed contiguously to the needle punch portion 28a formed at the first piercing step 26.

By repeating the first piercing step 26 and the second piercing step 27 by a predetermined number of times, the needle punch working portion 20 is formed with the slender cords 17 in the direction orthogonal to the carrying direction by the needle punch portions 28a, 28b, at respective intervals of the distance dimension Q (5 mm).

Thereafter, as shown by FIG. 5, at the back face side member forming step 30, after bonding the base cloth 19 to the side face of the needle punch working portion 20 formed with the slender cords 17 by the first piercing step 26 and the second piercing step 27 opposed to the slender cords 17 in a thickness direction by thermal press contact means or the like, at the carpet matrix bonding means 31, the carpet matrix 14 is bonded to the surface of the base cloth 19 by way of an adhering agent or the like.

Thereafter, at the thermoplastic resin spraying step 32, the thermoplastic resin 24 constituting the acrylic species resin is sprayed to the needle punch working portion 20 of the back face side member 15 by a spray.

By the drying step 33, by drying the thermoplastic resin 24, the vehicle mounting carpet 10 is finished.

According to the method, by adjusting the dimension of the needle punch working portion 20 carried during one time piercing operation to be the half of the interval dimension P (distance dimension Q) of the needle punch needles 21 contiguous to each other in the same needle row, the slender cords 17 in the direction orthogonal to the carrying direction can easily be formed at the needle punch working portion 20 without reforming the general needle punch working apparatus.

Meanwhile, the pile 13 of the carpet matrix 14 is slightly inclined in a predetermined direction, a direction of inclination is referred to as a forward direction and a direction reverse thereto is referred to as a backward direction.

In the carpet matrix bonding step 31 shown in FIG. 5, when the carpet matrix 14 is bonded to the back face side member 15, generally, the bonding is carried out such that the pile 13 of the carpet matrix 14 constitutes a forward direction or a backward direction relative to the carrying direction.

Further, when the finished vehicle mounting carpet 10 is laid at inside of a vehicle compartment, with an object of promoting an outlook quality by a visual sensation of a passenger, generally, the pile 13 is laid to constitute the forward direction or the backward direction relative to a direction of advancing the vehicle body.

When the cord is formed by a general needle punch working step without depending on the fabricating method, a cord of a shape along a direction of the carrying direction in the needle punch working is constituted.

Therefore, since the width direction of the formed cord and the direction of inclining the direction of the pile are orthogonal to each other, when the vehicle mounting carpet is laid such that the cord constitutes the width direction of the vehicle body, the pile is brought into a state of being inclined to one side in the width direction of the vehicle body, a color in a visual sensation of the pile is changed from that when optically recognized from the forward or the rearward direction of the pile and the outlook quality by the visual sensation of the passenger is deteriorated.

In contrast thereto, according to the fabricating method shown in the embodiment, as shown by FIG. 5, at the carpet bonding step 31, the pile 13 is bonded to the back face side member 15 in the state of constituting the forward direction or the rearward direction relative to the carrying direction, the slender cord 17 is bonded to be substantially orthogonal to the forward direction or the backward direction, the respective rows of the slender cords 17 formed along the direction orthogonal to the carrying direction are aligned along the carrying direction. Therefore, the direction of inclining the forward or the backward direction of the pile and the direction of aligning cords 17 coincide with each other.

Therefore, by cutting the carpet matrix 14 by predetermined dimensions after bonding, when the carpet matrix is aligned such that the respective rows of the slender cords are aligned to arrange along the width direction of the vehicle body, the direction of the pile 13 is brought into a state of being forward or backward relative to the direction of advancing the vehicle body. There is also achieved an effect of capable of easily fabricating the vehicle mounting carpet 10 by only pertinently adjusting a carrying speed in needle punch working without changing a constitution of the needle punch working apparatus.

The invention is applicable to the vehicle mounting carpet laid at inside of the vehicle compartment of the automobile and its fabricating method and the invention is not limited by the examples.





 
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