Sound absorbing carpet and method for maunfacturing the same

Abstract

A sound absorbing carpet according to the present invention is characterized in that a sound absorbing nonwoven fabric layer is integrally bonded to a lower surface side of the surface skin material layer via an adhesive film layer made of thermoplastic resin, and a part of fibers constituting the sound absorbing nonwoven fabric layer are constituted by thick fibers of 11 to 220 desitex, and the adhesive film layer is provided with a number of permeable pores formed by being contacted by the thick fibers.

1 . A sound absorbing carpet, comprising:
 a surface skin material layer; and   a sound absorbing nonwoven fabric layer integrally bonded to a lower surface side of the surface skin material layer via an adhesive film layer made of thermoplastic resin,   wherein a part of fibers constituting the sound absorbing nonwoven fabric layer are constituted by thick fibers of 11 to 220 desitex, and   wherein the adhesive film layer is provided with permeable pores formed by being contacted by the thick fibers.   
   
   
       2 . The sound absorbing carpet as recited in  claim 1 , wherein a part of the thick fibers are embedded in the adhesive film layer and tangled therewith. 
   
   
       3 . The sound absorbing carpet as recited in  claim 1 , wherein thick fibers of 11 to 220 desitex and first fibers of 1 to 10 desitex are used as fibers constituting the sound absorbing nonwoven fabric layer. 
   
   
       4 . The sound absorbing carpet as recited in  claim 3 , wherein the sound absorbing nonwoven fabric layer is made of nonwoven fabric in which the thick fibers are upwardly protruded from an upper surface of a nonwoven fabric base layer formed by the thick fibers and the first fibers. 
   
   
       5 . The sound absorbing carpet as recited in  claim 4 , wherein a combined mass ratio of the fibers constituting the sound absorbing nonwoven layer is thick fibers/first fibers=5/95 to 99/1. 
   
   
       6 . The sound absorbing carpet as recited in  claim 1 , wherein an amount of the sound absorbing nonwoven fiber layer is 150 to 1,000 g/m 2 . 
   
   
       7 . The sound absorbing carpet as recited in  claim 1 , wherein an amount of the adhesive film layer is 5 to 300 g/m 2 . 
   
   
       8 . The sound absorbing carpet as recited in  claim 1 , wherein the adhesive film layer contains the thermoplastic resin and filler. 
   
   
       9 . The sound absorbing carpet as recited in  claim 1 , wherein, as the surface skin material layer, carpet cloth in which pile is embedded in an upper surface of a base fabric having a precoat processed lower surface is used. 
   
   
       10 . The sound absorbing carpet as recited in  claim 1 , wherein a needle punched nonwoven fabric is used as the surface skin material layer. 
   
   
       11 . A sound absorbing carpet, comprising:
 a surface skin material layer; and   a sound absorbing nonwoven fabric layer integrally bonded to a lower surface side of the surface skin material layer via an adhesive film layer made of thermoplastic resin,   wherein the sound absorbing nonwoven fabric layer is made of nonwoven fabric in which thick fibers of 11 to 220 desitex are upwardly protruded from an upper surface of a nonwoven fabric base layer formed by the thick fibers and first fibers of 1 to 10 desitex,   wherein the adhesive film layer is provided with permeable pores formed by being contacted by the thick fibers,   wherein a part of the thick fibers are inserted in the adhesive film layer and tangled therewith,   wherein a combined mass ratio of the fibers constituting the sound absorbing nonwoven layer is thick fibers/first fibers=5/95 to 99/1.   wherein an amount of the sound absorbing nonwoven fiber layer is 150 to 1,000 g/m 2 , and   wherein an amount of the adhesive film layer is 5 to 300 g/m 2 .   
   
   
       12 . A method of manufacturing a sound absorbing carpet, the method comprising:
 superimposing nonwoven fabric in which thick fabrics of 11 to 220 desitex are used as a part of fibers constituting the nonwoven fabric, an adhesive film of thermoplastic resin obtained immediately after extrusion and a surface skin material in this order; and   pressing them by and between a pair of rollers.   
   
   
       13 . The method of manufacturing a sound absorbing carpet as recited in  claim 12 , wherein, using nonwoven fabric in which thick fibers of 11 to 220 desitex are upwardly protruded from an upper surface of a nonwoven fabric base layer formed by the thick fibers and first fibers of 1 to 10 desitex as the sound absorbing nonwoven fabric layer, the nonwoven fabric, the adhesive film and the surface skin material are pressed by and between a pair of rollers in a state in which an upwardly protruded thick fiber side is in contact with the adhesive film. 
   
   
       14 . The method of manufacturing a sound absorbing carpet as recited in  claim 12 , wherein a pressing roller is used as one of the pair of rollers and a cooling roller is used as the other of the pair of rollers.