Main carpet assembly in automobile passenger compartment and preparation method of main carpet assembly

Abstract

The invention relates to a main carpet assembly in an automobile passenger compartment and a preparation method of the main carpet assembly, the main carpet assembly in the automobile passenger compartment comprises an appearance fabric layer (1) and a sound insulation pad framework layer (2) which are formed and compounded through a one-step method, a wear-resistant foot pad (3) is welded to a main driving pedal area of the appearance fabric layer (1), and meanwhile a foot pad buckle base (4) is installed in a main and co-driving area. Compared with the prior art, the carpet is integrally formed through a one-step method, the fitting degree of the appearance carpet surface and the framework layer is improved, the hardness of the framework part can be adjusted according to actual requirements, and the supporting function and the sound absorption and noise reduction function are achieved at the same time; meanwhile, the production efficiency is greatly improved, and the material cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of automobile accessories, in particular to a main carpet assembly in an automobile passenger compartment and a preparation method thereof. Background Art

[0002] At present, the main carpet parts in the passenger compartment of the automobile industry are basically supplied in one piece with the main carpet and the sound insulation pad under the carpet. Currently, these parts are formed separately and then compounded with hot melt adhesive. The molding result is not very fit, and the molding performance of the carpet layer alone is very poor. An additional skeleton layer must be added to improve the molding performance of the carpet layer. Summary of the invention

[0003] The purpose of the present invention is to provide a main carpet assembly for a passenger compartment of a vehicle and a method for preparing the same in order to overcome the defects of the prior art.

[0004] The objective of the present invention can be achieved through the following technical solutions: a main carpet assembly in a car passenger compartment, comprising an exterior fabric layer and a sound insulation pad skeleton layer formed in a one-step composite manner, wherein a wear-resistant foot pad is welded to the main driver's footrest area of ​​the exterior fabric layer, and a foot pad clip base is installed in the main and co-driver areas.

[0005] Preferably, the appearance fabric layer is made of PET, with a thickness of 2-7 mm and a gram weight of 400-720 g / m 2 .

[0006] Preferably, a hot melt adhesive layer is provided between the appearance fabric layer and the sound insulation pad skeleton layer.

[0007] Further preferably, the hot melt adhesive layer is a PE adhesive film with a thickness of 0.5 to 3 mm and a gram weight of 80 to 400 g / m 2 .

[0008] Preferably, the main carpet assembly in the passenger compartment of the vehicle further includes other accessories.

[0009] A method for preparing the above-mentioned main carpet assembly in the passenger compartment of an automobile comprises the following steps:

[0010] The sound insulation pad skeleton layer is embedded in a one-step molding composite mold, and the baked appearance fabric layer with a hot melt adhesive layer on the back is laid in the one-step molding composite mold, and molded, cooled and formed to obtain a molded composite part;

[0011] A wear-resistant foot pad is welded on the molded composite part and a foot pad buckle base is installed.

[0012] Preferably, the sound insulation pad skeleton layer is pre-embedded in a lower mold of a further composite mold.

[0013] Preferably, the one-step forming composite mold is provided with a groove matching the shape of the sound insulation pad skeleton layer.

[0014] Further preferably, the thickness of the sound insulation pad skeleton layer is not less than the depth of the groove.

[0015] More preferably, the thickness of the sound insulation pad skeleton layer is greater than the depth of the groove, and the upper surface protrudes from the groove.

[0016] Preferably, the molding pressure of the molding cooling and shaping is 5-12Mpa, the cooling temperature is 5-20°C, and the cooling time is 45-60sec.

[0017] Preferably, the sound insulation pad skeleton layer is made of cloth flowers, molten fibers and sponge particles in a weight ratio of (50-62): (35-45): (3-5) as raw materials, and is sequentially formed by a forming mesh mold, an oven mesh mold, a forming mesh mold and a punching mold.

[0018] In the present invention, the hardness and softness of the sound insulation pad skeleton layer can be adjusted by adjusting the density of the sound insulation pad skeleton layer and the ratio of raw materials.

[0019] Further preferably, the method for preparing the sound insulation pad skeleton layer comprises the following steps:

[0020] S1: Putting the cloth flowers, molten fibers and sponge particles into an opener at a weight ratio of (50-62): (35-45): (3-5) for air flow mixing, and sending the mixed raw materials into a wool storage box behind the vibration bin;

[0021] S2: closed filling and forming mesh mold;

[0022] S3: Use the vibration chamber to evenly spread the raw materials on the conveyor belt, and use the yarn spreading fan to blow the raw materials into the filling and forming mesh mold; after the filling is completed, the filling and forming mesh mold automatically opens to form a fiber cake;

[0023] S4: The filled fiber cake is sent to a heating oven through a conveyor belt. A pair of oven mesh molds are provided on the upper part of the heating oven. The oven mesh molds are closed to fix the fiber cakes, and hot air is turned on for heating and forming. The heating temperature is controlled to be 180-250°C and the heating is performed for 25-45 seconds. After the heating is in place, the oven mesh molds are opened and the heating of the fiber cakes is completed.

[0024] S5: conveying the heated fiber cake by a conveyor belt and spreading it into a forming mesh mold, closing the forming mesh mold, cooling and shaping it with cold air, the cooling time is 25 to 45 seconds, and obtaining a formed part;

[0025] S6: placing the formed component on a punching die, closing the die and punching out the edge material, so as to obtain a semi-finished sound insulation pad, namely, the sound insulation pad skeleton layer.

[0026] Preferably, the baking temperature of the appearance fabric layer with a hot-melt adhesive layer on the back is 160-270° C., and the baking time is 40-120 min.

[0027] Preferably, the baked appearance fabric layer with a hot-melt adhesive layer on the back is laid in a one-step forming composite mold by a conveyor belt, and then molded, cooled and formed.

[0028] Preferably, after obtaining the molded composite part, the molded composite part is placed on the welding assembly tooling, and the corresponding wear-resistant foot pads and foot pad buckle bases are laid out and placed in corresponding positions, and the corresponding equipment is started to complete the welding and installation;

[0029] Place the welded and installed parts on the corresponding water jet cutting bracket, start the corresponding water jet cutting program to complete the cutting and obtain the finished product.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] 1. The fabric of the present invention reduces the PET skeleton layer, and directly uses the sound insulation pad to replace the original PET skeleton layer, which reduces the composite process, the surface carpet and the sound insulation pad have a higher fit, better performance, and at the same time reduces the cost of the original PET skeleton layer;

[0032] 2. The present invention adopts one-step integrated molding, which improves the fit between the exterior carpet surface and the skeleton layer. The skeleton part can be adjusted in softness and hardness according to actual needs, which plays a supporting role while also playing a role of sound absorption and noise reduction;

[0033] 3. The present invention can greatly improve production efficiency and reduce material costs;

[0034] 4. In the present invention, the adhesive uniformity of the main carpet assembly in the passenger compartment of the automobile is good. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a cross-sectional view of the main carpet assembly in the passenger compartment of the automobile of the present invention;

[0036] Figure 2 A top view of the main carpet assembly in the passenger compartment of a vehicle of the present invention;

[0037] Figure 3 This is a schematic diagram of the working principle of the one-step forming composite mold of the present invention;

[0038] Figure 4 is a cross-sectional view of the main carpet assembly in the passenger compartment of a vehicle of Comparative Example 1;

[0039] Figure 5 The sound absorption characteristic curve diagram of the main carpet assembly in the passenger compartment of the automobile of the present invention;

[0040] In the figure: 1-appearance fabric layer, 2-sound insulation pad skeleton layer, 3-wear-resistant foot pad, 4-foot pad buckle base, 5-hot melt adhesive layer, 6-mold, 7-PET skeleton layer. DETAILED DESCRIPTION

[0041] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0042] Comparative Example 1

[0043] A method for preparing a main carpet assembly in a passenger compartment of an automobile comprises the following steps:

[0044] (1) Put the cloth flowers, molten fibers and sponge particles into an opener in a weight ratio of (50-62):(35-45):(3-5) for air flow mixing, and send the evenly mixed raw materials into a wool storage box behind the vibration bin.

[0045] (2) Close the filling and forming mesh mold.

[0046] (3) The raw materials are evenly spread on the conveyor belt using a vibration chamber, and the raw materials are blown into the filling and molding mold by a yarn laying fan; after the filling is completed, the mold automatically opens to form a fiber cake; different density parameters can be adjusted for different parts.

[0047] (4) The filled fiber cake is sent to the heating oven through a conveyor belt. There is a pair of oven mesh molds on the upper part of the oven. The oven mesh molds are closed to fix the fiber cake, and hot air is turned on to heat and shape it. The heating temperature is controlled to be 180-250°C, and the heating is carried out for 25-45 seconds. After the heating is in place, the mold is opened. The fiber cake is heated.

[0048] (5) The heated fiber cake is conveyed and spread into a forming mesh mold by a conveyor belt, the mold is closed, and cold air is used to cool and shape the fiber cake. The cooling time is 25 to 45 seconds to obtain a formed part.

[0049] (6) The formed component is placed on a punching die, and the die is closed to punch out the edge material, thereby obtaining a semi-finished sound insulation pad (sound insulation pad skeleton layer 2).

[0050] (7) The carpet is baked and heated, and then cooled and formed to obtain a semi-finished carpet fabric layer (appearance fabric layer 1) with a PET skeleton layer 7.

[0051] (8) Place the semi-finished carpet on the welding assembly tooling, lay out the corresponding wear-resistant foot pads 3 and foot pad buckle bases 4 in the corresponding positions, start the corresponding equipment, and complete the welding and installation.

[0052] (9) The carpet is placed on a water jet cutting bracket for water jet cutting of the edge material to obtain a semi-finished carpet fabric.

[0053] (10) The carpet fabric (the appearance fabric layer 1 with the PET skeleton layer 7) and the semi-finished sound insulation pad (the sound insulation pad skeleton layer 2) are compounded by a compounding tool (hot melt adhesive (hot melt adhesive layer 5) is used as an adhesive in the whole process) to obtain a carpet having the following characteristics: Figure 4 Products with the structure shown.

[0054] Example 1

[0055] A one-step main carpet assembly, wherein an appearance fabric layer 1 and a sound insulation pad skeleton layer 2 are formed in one step to obtain a product, and unlike conventional products, they do not need to be formed separately and then composited.

[0056] like Figures 1-2 As shown, the exterior fabric layer 1 and the main driver's footrest area are welded with wear-resistant foot pads 3, and foot pad buckle bases 4 are installed in the main and co-driver areas to facilitate users to install the foot pads later.

[0057] A method for manufacturing the one-step main carpet assembly comprises the following steps:

[0058] (1) Put the cloth flowers, molten fibers and sponge particles into an opener in a weight ratio of (50-62):(35-45):(3-5) for air flow mixing, and send the evenly mixed raw materials into a wool storage box behind the vibration bin.

[0059] (2) Close the filling and forming mesh mold.

[0060] (3) Use the vibration chamber to evenly spread the raw materials on the conveyor belt, and use the yarn spreading fan to blow the raw materials into the filling and molding mold; after filling, the mold automatically opens to form a fiber cake; different parts can adjust different density parameters (60-300kg / m 3 ).

[0061] (4) The filled fiber cake is sent to the heating oven through a conveyor belt. There is a pair of oven mesh molds on the upper part of the oven. The oven mesh molds are closed to fix the fiber cake, and hot air is turned on to heat and shape it. The heating temperature is controlled to be 180-250°C, and the heating is carried out for 25-45 seconds. After the heating is in place, the mold is opened. The fiber cake is heated.

[0062] (5) The heated fiber cake is conveyed and spread into a forming mesh mold by a conveyor belt, the mold is closed, and cold air is used to cool and shape the fiber cake. The cooling time is 25 to 45 seconds to obtain a formed part.

[0063] (6) The formed component is placed on a punching die, and the die is closed to punch out the edge material to obtain a semi-finished sound insulation pad.

[0064] (7) Figure 3 As shown, the semi-finished sound insulation pad is embedded in a further forming composite mold 6, and the baked fabric (with a PE film (hot melt adhesive layer 5) on the back) is laid in the forming composite mold 6 by a conveyor belt, and molded and cooled for shaping. The cooling time is 45 to 60 seconds to obtain a molded composite part, in which the fabric reduces the PET skeleton layer, and the sound insulation pad is directly used to replace the original PET skeleton layer, which reduces the composite process, and the surface carpet and the sound insulation pad have a higher fit and better performance, while reducing the cost of the original PET skeleton layer.

[0065] (8) Place the molded composite parts on the welding assembly tooling, lay out the corresponding wear-resistant pads and pad buckles in the corresponding positions, start the corresponding equipment, and complete the welding and installation.

[0066] (9) Place the welded and installed parts on the corresponding water jet cutting bracket, start the corresponding water jet cutting program to complete the cutting. The water jet cutting can be adjusted at any time according to customer needs to obtain the finished product.

[0067] The sound absorption performance of the two main carpet assemblies with an average thickness of 21 mm prepared by the method of this embodiment was tested on both the front and back sides. The results are as follows: Figure 5 As shown, it is shown that the main carpet assembly of the present invention can play a good role in sound absorption and noise reduction.

[0068] The above description of the embodiments is to facilitate the understanding and use of the invention by those skilled in the art. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative work. Therefore, the present invention is not limited to the above embodiments, and improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the scope of protection of the present invention.

Claims

1. A main carpet assembly in a passenger compartment of a vehicle, characterized in that: The invention comprises a composite appearance fabric layer (1) and a sound insulation pad skeleton layer (2) formed by a one-step method, wherein a wear-resistant foot pad (3) is welded to the main driving footrest area of ​​the appearance fabric layer (1), and a foot pad buckle base (4) is installed in the main and co-driver areas.

2. The main carpet assembly in the passenger compartment of a vehicle according to claim 1, characterized in that: The appearance fabric layer (1) is made of PET, has a thickness of 2 to 7 mm, and a gram weight of 400 to 720 g / m 2 .

3. The main carpet assembly in the passenger compartment of a vehicle according to claim 1, characterized in that: A hot melt adhesive layer (5) is provided between the appearance fabric layer (1) and the sound insulation pad skeleton layer (2).

4. The main carpet assembly in the passenger compartment of a vehicle according to claim 3, characterized in that: The hot melt adhesive layer (5) is a PE adhesive film with a thickness of 0.5 to 3 mm and a gram weight of 80 to 400 g / m 2 .

5. A method for preparing the main carpet assembly in the passenger compartment of an automobile according to any one of claims 1 to 4, characterized in that: The following steps are involved: The sound insulation pad skeleton layer (2) is embedded in a one-step forming composite mold (6), and the baked appearance fabric layer (1) with a hot melt adhesive layer (5) on the back is laid in the one-step forming composite mold (6), and molded, cooled and formed to obtain a formed composite part; A wear-resistant foot pad (3) is welded on the molded composite part and a foot pad buckle base (4) is installed.

6. The method for preparing the main carpet assembly in the passenger compartment of an automobile according to claim 5, characterized in that: The molding pressure of the molding cooling and shaping is 5-12Mpa, the cooling temperature is 5-20°C, and the cooling time is 45-60sec.

7. The method for preparing the main carpet assembly in the passenger compartment of an automobile according to claim 5, characterized in that: The sound insulation pad skeleton layer (2) is made of cloth flowers, molten fibers and sponge particles in a weight ratio of (50-62):(35-45):(3-5) as raw materials, and is prepared in sequence by a forming mesh mold, an oven mesh mold, a forming mesh mold and a punching mold.

8. The method for preparing the main carpet assembly in the passenger compartment of an automobile according to claim 5, characterized in that: The baking temperature of the appearance fabric layer (1) with the hot melt adhesive layer (5) on the back is 160-270° C., and the baking time is 40-120 minutes.

9. The method for preparing the main carpet assembly in the passenger compartment of an automobile according to claim 5, characterized in that: The baked appearance fabric layer (1) with a hot melt adhesive layer (5) on the back is laid in a one-step forming composite mold through a conveyor belt, and then molded, cooled and formed.

10. The method for preparing the main carpet assembly in the passenger compartment of an automobile according to claim 5, characterized in that: After obtaining the formed composite part, the formed composite part is placed on the welding assembly tool, and the corresponding wear-resistant foot pad (3) and the foot pad buckle base (4) are laid out and placed in the corresponding position, and the corresponding equipment is started to complete the welding and installation; Place the welded and installed parts on the corresponding water jet cutting bracket, start the corresponding water jet cutting program to complete the cutting and obtain the finished product.

Images