Vehicle mounting carpet and producing method thereof

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.

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.