JPH0554420B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION FIELD OF INDUSTRIAL APPLICATION This invention relates to a method for manufacturing a plastic floor covering for the passenger compartment or luggage compartment of a microbus or light van.

BACKGROUND OF THE INVENTION Conventionally, the floor of such an automobile cabin is generally constructed of a press-formed steel plate having a corrugated cross section in order to improve rigidity, and the upper surface has an uneven striped surface showing the corrugation. As a result, it was inconvenient for passengers to walk and to store their luggage.

Problems to be Solved by the Invention For this purpose, a plywood board is laid on the top surface of the floor to make it flat, but vibrations and noise of the vehicle body are amplified due to resonance between the floor and the plywood board, causing discomfort to the passengers. Ta. In addition, it has been attempted to lay a synthetic resin or rubber sheet on top of the plywood, or to lay a thick carpet on top of it, but this has not been satisfactory.

SUMMARY OF THE INVENTION An object of the present invention is to eliminate such drawbacks and provide a method for manufacturing a floor covering that provides a flat floor surface and prevents the propagation of vibrations and noise from the floor.

Means for Solving the Problems In order to achieve this object, in the method of manufacturing a plastic floor covering for an automobile cabin according to the present invention, the following steps are successively carried out.

(b) A combination of three or four components selected from plasticizers, rubbers, fillers, and post-aging substances to the main component, which is a thermoplastic synthetic resin kneaded and melted using an intensive mixer, extruder, or mixing roll. A first step in which the floor covering material consisting of the material is supplied from above the nip between the warmer rolls by a conveying device.

(b) A second step in which the supplied floor covering material is made into a continuous sheet having a predetermined thickness and width and is fed between the mold roll and the flat roll in the warming roll.

(c) A mold roll in which a concave portion consisting of a single concave groove, a plurality of small concave grooves, or an aggregate of small concave concave portions is carved, which approximately corresponds to the shape of each concave strip on the top surface of a corrugated steel sheet for an automobile passenger compartment. and a cylindrical flat roll, the sheet-like floor covering material is rolled into a uniform sheet with a width and protrusion dimension that corresponds to the shape of each concave strip on the upper surface of the corrugated steel sheet and approximately matches the width and depth of the concave strip. A third step of forming a floor covering having a convex portion consisting of a convex strip or a plurality of small convex stripes or an aggregate of small convexities, and supplying it onto a cooling conveyor.

(d) A fourth step in which the molded bed sheet supplied on the cooling conveyor is cooled, transferred to a cutting table, and cut into products.

In addition, when the skin material is applied to the flat side of the molded floor covering that is on the surface of the mold roll, or when the skin material is applied from the flat roll side, the skin material is applied from the flat roll side to the flat side of the molded floor covering. In some cases, the bedding material is formed and simultaneously attached to the flat side of the bedding body, or the skin material may be adhered to the flat side of the bedding body cut in the fourth step.

Function: In the method of manufacturing a plastic floor covering for an automobile cabin of the present invention, a convex portion having a width and protrusion dimension corresponding to each concave strip on the upper surface of a corrugated steel plate floor of an automobile cabin is formed, the upper surface is flat, and A floor covering that can control vibrations and block noise through steel plates is made of a material whose main component is thermoplastic synthetic resin and a combination of three or four types of components, and is made continuously into a predetermined shape. It can be manufactured efficiently.

Embodiments Examples of the floor covering manufactured by the present invention will be described in detail with reference to the drawings.

FIG. 1 is a cross-sectional view of a main part showing a state in which an example of a floor covering manufactured by the present invention is laid on a floor.
As shown in FIG. 9 as an example of the overall plan view of the floor 1 of the automobile compartment, a large number of grooves 3 having a corrugated cross section are press-formed to improve rigidity.
A width w2 and a protrusion dimension d corresponding to the shape of each of the grooves 3 and substantially matching the width w1 and depth dimension d1 thereof.
A floor covering 2 on which a convex portion consisting of two convex stripes 4 is formed is laid on the upper surface of the floor 1.

FIG. 2 is a perspective view of the main parts of the floor covering 2 when it is turned over. The floor covering 2 material is mainly composed of general-purpose thermoplastic resins such as vinyl chloride resin, polyethylene, and polypropylene, as well as plasticizers such as dioctyl phthalate (DOP), dihexyl phthalate (DHP), and dibutyl phthalate (DBP), and nitrile. Fillings such as rubber, various rubbers such as ethylene/propylene rubber, thermoplastic rubber, and atactic polypropylene, calcium carbonate, talc, barium sulfate, mica, asbestos, rice husk powder, wood flour, and chip strands of natural or synthetic fibers. This material is a combination of three or four components selected from bituminous substances such as silica and bituminous substances such as straight asphalt, blown asphalt, and natural asphalt.

These materials are kneaded and melted using an intensive mixer, extruder, or mixing roll, and then molded using a forming mold roll and a flat roll or extrusion die to form a concave strip with a flat upper surface and a lower surface in the shape of the floor 1 of an automobile passenger compartment. Correspondingly, a floor covering 2 is manufactured in which a protruding strip 4 having a width w2 and a protrusion dimension d2 substantially matching the width w1 and depth dimension d1 is formed.

Woven fabric, non-woven fabric, knitted fabric,
A floor covering 2 with a skin 9 as shown in FIG. 3 to which a skin material selected from carpets and thermoplastic resin sheets is attached with or without adhesive.
There is also.

The upper surface of such a floor covering 2 is flat, and the lower surface corresponds to the shape of the numerous grooves 3 of the press-formed corrugated steel plate floor 1 to be laid, and has a width w1.
Since the recessed strip 4 is formed with a width w2 that substantially matches the depth dimension d1 and a protrusion dimension d2, by laying it in the passenger compartment, vibrations of the corrugated steel plate floor 1 can be suppressed.
Since the intrusion of noise through the floor 1 is blocked, a comfortable living space is provided to the passengers. At this time, if the upper surface of the floor 1 and the lower surface of the floor covering 2 are entirely fixed with an adhesive or adhesive, the effect of suppressing the vibration of the floor 1 can be further enhanced.

Further, as an example of another form of the floor covering manufactured by the present invention, for example, as shown in FIG.
The protruding strip 4 of the floor covering 2a inserted into one concave strip 3 of the floor 1 is divided into several small protruding strips 41, and the convex portion consisting of a series of small protruding strips 41 is formed on the floor 1. Corresponding to the shape of the groove, the width w2 and the protrusion dimension d2 may be set to substantially match the width w1 and depth dimension d1.
In this case, although the vibration damping effect of the floor covering 2a is slightly inferior to that of the above embodiments, the weight of the floor covering 2a can be reduced.

As an example of still another form, for example, the fifth
As shown in the figure, the protruding stripes 4 of the floor covering 2b are divided into a large number of small protrusions 42, and the protrusions made of a group of small protrusions 42 are shaped like the concave strips of the floor 1. Correspondingly, a width w that substantially matches the width w1 and depth dimension d1
2 and the protrusion dimension d2. In this case, the weight of the floor covering 2b can be significantly reduced, and it has a vibration damping effect and a sound insulation effect that do not cause discomfort to passengers.

Next, an embodiment of the method for continuously manufacturing a floor covering according to the present invention will be described in detail with reference to the drawings.

FIG. 6 is an explanatory diagram of a series of devices for manufacturing the floor covering 2. As shown in FIG.

In the first step, a material consisting of a main component consisting of a thermoplastic synthetic resin and a combination of three or four components selected from plasticizers, rubbers, fillers, and bituminous substances is kneaded using, for example, an intensive mixer 10. After being melted, it is dropped onto a pair of mixing rolls 11 to be kneaded again, and then dropped onto a belt of a conveying device 12, and this floor covering material 13 is fed into the nip of a pair of warming rolls 14 and 15 from above.

Each component of the floor covering material 13 is as described above, for example, 100 parts by weight of vinyl chloride resin, DOP70
parts by weight, a combination of 40 parts of calcium carbonate and 140 parts of mica, 100 parts by weight of low density polyethylene, 40 parts by weight of calcium carbonate, 50 parts by weight of talc and blown asphalt 20 with a penetration rate of 15 (25°C, 100 g, 5 seconds) Combination of parts by weight, 100 parts by weight of polypropylene, 30 parts by weight of atactic polyethylene, talc
The parts by weight and type of each component are selected and blended in order to enhance the properties required for the flooring material 2, especially vibration damping and sound insulation effects, such as a combination of 50 parts by weight and 20 parts by weight of wood flour.

In addition to the intensive mixer 10, the kneading may be performed using an extruder or directly using a mixing roll. Note that the mixing roll 11 side of the conveying device 12 is used as a fulcrum, and only the warming rolls 14 and 15 sides are moved periodically while changing speed in the vertical direction of the paper of FIG. 6, and the floor covering material 13 is continuously delivered.
By supplying the nips of the warming rolls 14 and 15 in a partially varying manner, the amount of bank in the nips can be made uniform.

In the second step, the supplied floor covering material 16 is further kneaded and homogenized between a pair of warming rolls 14 and 15, and its width is cut by two cutting blades 17 whose interval is variable in the axial direction of the warming roll. The thickness is determined by adjusting the distance between the warming rolls 14 and 15, and each sheet is formed into a continuous sheet 18 having a predetermined width and thickness.
9 and the flat roll 20.

The unnecessary portions of material on both sides cut by the two cutting blades 17 return to the nip portion as they rotate around the warming roll 15.

In the third step, the supplied sheet 18-shaped floor covering material is transferred to a mold roll 19 and a cylindrical flat roll 20.
It is formed into the shape of the floor covering 2 between the two.

The cross sections of the mold roll 19 and the flat roll 20 are as shown in FIG. 7, for example, and the mold roll 19 has a plurality of grooves 30 formed on its circumferential surface. Furthermore, in order to manufacture the floor covering 2a as shown in FIG. 4, the collection of small grooves 31 corresponding to the small protrusions 41 may be formed into one recess, as shown in FIG. 7a. The grooves 30 or the grooves made of the small groove polymer approximately correspond to the shapes of the grooves 3 on the upper surface of the corrugated steel plate floor of the automobile cabin. In some cases, the peripheral surface of the flat roll 20 is also engraved with a grain pattern.

The forming die roll 19 illustrated in FIG. 7 or FIG. 2a, the distance between the mold roll 19 and the flat roll 20 is determined corresponding to the thickness of the non-convex strip portion of the floor covering 2.
When molding such floor coverings 2, 2a, the rotational speed of the mold roll 19 and the flat roll 20 is set at a surface speed ratio of 1:1.02 to 1:1.12.
If it is set within the range of , the ridgeline of the protruding strip 4 or the small protruding strip 41 will clearly appear. If the surface circumferential velocity ratio is less than the above, the ridgeline will become unclear, and if it exceeds, distortion will remain in the non-convex portions of the floor coverings 2, 2a.

When the convex portion of the floor covering 2b is composed of a large number of independent small protrusions 42 as shown in FIG. It is sufficient to carve a recessed portion at a predetermined position on the circumferential surface of the mold roll 19a. When molding such a floor covering 2b, a mold roll 19a and a flat roll 2 are used.
It is preferable to set the rotation speed at 0 so that the surface peripheral speed ratio of each roll is within the range of 1:0.85 to 1:0.95. When the surface peripheral speed ratio is less than the above, the supplied sheet 18 material is
If the air does not enter the small depressions 32 on the peripheral surface or exceeds the area, the air in the small depressions 32 cannot escape, causing the floor covering 2b
The top of the small protrusion 42 may be chipped. In addition, when forming such a floor covering 2b, a sheet 18-shaped material is supplied from the flat roll 20 side, and the peripheral surface of the flat roll 20 is aligned for 1/5 rotation to form a bank of the material. If the air is generated on the flat roll 20 side, the above-mentioned air containment phenomenon will disappear.

Furthermore, if the plan view of the corrugated steel plate floor 1 of an automobile cabin is as shown in FIG. 9, and the A-A sectional view thereof is as shown in FIG. Since there are some parts that are not
In order to manufacture the floor covering 2 to be laid on the
As shown in the figure, the floor 1 is placed on the circumference of the mold roll 19b, whose circumference is the maximum length in the vertical or horizontal direction of the floor 1, and whose effective width is the maximum length in the horizontal or vertical direction, respectively.
A groove 33 is carved in a position and shape corresponding to each groove 3 . At this time, the outer roll 1 on which the concave groove 33 is carved
9c is inserted into the outer peripheral surface of the inner roll 19d, or the outer roll 19c is divided into a plurality of pieces and fixed to the inner roll 19d in a freely attachable manner.
The manufacturing cost of the mold roll 19b due to changes in the design of the floor 1 is reduced.

In the third step, the floor covering 2 formed between the mold roll 19 and the flat roll 20 runs along the circumferential surface of the mold roll 19 for about one-fourth of a turn, and then
It is dropped onto the cooling conveyor 22. During this time, as shown in FIG. 6, the flat side of the floor covering 2 is pressed by the push roll 21, thereby further increasing the flatness of the floor covering 2.

In the fourth step, the floor covering 2 on which the protrusions 4 have been formed is supplied to the cooling conveyor 22, while being moved on the cooling conveyor 22, is cooled by cold air or cold water by the cooling device 23, and then transferred to the cutting table 24. Feed cutting blade 25
By cutting both sides or the four circumferences of the floor covering 2, a product is obtained.

As mentioned above, the first to fourth steps of this invention are carried out continuously as shown in Figure 6, so there is no repetition of heating and cooling of the material, and the thermal history of the material is minimized. As a result, thermal deterioration of the material is kept to a minimum, and during the third step when forming the sheet into a predetermined shape, the temperature difference between the outside and inside of the supplied sheet is extremely small, so there is no distortion and post-deformation. It is possible to manufacture products with clear edges and sharp edges.

In addition, in order to manufacture the floor covering 2 shown in FIG. 3 with the skin 9 adhered to the flat side, as shown in FIG.
are sequentially fed out, and the display material 26 is preheated with a heating device 27 or coated with adhesive as necessary, and pasted on the flat side of the bedding body 2 on the circumferential surface of the mold roll 19 by pressing with a rubber roll 28. wear.

In addition to the supply method described above, the skin material 26 is supplied along the circumferential surface of the flat roll 20, and the convex strips 4 are formed on the floor covering material by the flat roll 20 and the mold roll 19. At the same time, the floor covering 2
A skin material 26 may be attached to the flat side of the holder. In this case, the surface peripheral speed of the flat roll 20 is
Unless the surface circumferential speed is the same as or slightly slower than the surface peripheral speed of 9, wrinkles may occur in the skin material 26.

Furthermore, the skin material 26 may be pressure-bonded to the flat side of the floor covering 2 cut in the fourth step via thermal bonding or adhesive, and the skin material 26 may be cut into the shape of the entire floor of the automobile cabin. .

Effects of the Invention Since the method for manufacturing a plastic floor covering for an automobile passenger compartment according to the present invention is configured as described above, it has the following effects.

The plastic floor covering for automobile cabins manufactured according to the present invention has a width and protrusion dimension that approximately corresponds to the width and depth of the grooves at the lower surface position relative to each groove on the upper surface of the corrugated steel plate floor of the automobile cabin. A convex portion is formed,
The top surface is flat, making it easy for passengers to walk and place luggage, and also suppresses vibrations from the steel plate floor.
It blocks noise through the steel plate and increases the comfort of the passenger compartment. Furthermore, by pasting the skin on the flat surface side of the floor covering, the interior of the vehicle can be made luxurious.

In the manufacturing method of the present invention, it has become possible to continuously and effectively manufacture the above-described bedding body into a predetermined shape that can fully exhibit the effects of the bedding body. In other words, a series of processes are carried out continuously, which improves thermal efficiency during manufacturing, reduces processing costs, shortens the thermal history during product processing, prevents thermal deterioration, and reduces distortion. It is possible to manufacture products with clear ridge lines without any post-deformation.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of essential parts showing an example of the floor covering manufactured by the present invention being laid on the floor, and FIG. 2 is a main part of the floor covering shown in FIG. 1 when it is turned over. A perspective view of a part, FIG. 3 is a cross-sectional view of a main part of a floor covering with a skin attached to the flat side, and FIGS. 4 and 5 are a state where a floor covering manufactured in another embodiment is turned over. FIG. 6 is an explanatory diagram of an apparatus showing an example of the method for manufacturing a floor covering of the present invention, FIG. 7 is an axial cross-sectional view of a mold roll and a flat roll, and FIG. 7a is an illustration of another 8 and 11 are perspective views of mold rolls used in another embodiment, FIG. 9 is a plan view showing an example of a corrugated steel plate floor, and FIG. It is a sectional view taken along the line A-A of FIG. 1... Floor, 2, 2a, 2b... Floor covering, 3...
Concave stripes, 4... Convex stripes, 9... Skin, 10... Intensive mixer, 11... Mixing roll, 1
2... Conveyance device, 13... Floor covering material, 14,1
5...Warming roll, 19...Mold roll, 20...Flat roll, 22...Cooling conveyor,
24... Cutting table, 26... Skin material, 28... Rubber roll, 30, 33... Concave portion, 31... Small groove,
32...Small depressions, 41...Small protrusions, 42...Small protrusions.

Claims (1)

[Scope of Claims] 1. A method for manufacturing a plastic floor covering for automobile passenger compartments, in which the following steps are carried out continuously: (a) thermoplastic material kneaded and melted in an intensive mixer, extruder, or mixing roll; A floor covering material consisting of a combination of synthetic resin as the main component and three or four components selected from plasticizers, rubber, fillers, and bituminous substances is supplied from above to the nip between warming rolls by a conveying device. (b) A second step in which the supplied floor covering material is formed into a continuous sheet having a predetermined thickness and width in a warming roll and then fed between a mold roll and a flat roll. (c) A mold roll in which a concave portion consisting of a single concave groove, a plurality of small concave grooves, or an aggregate of small concave concave portions is carved, which approximately corresponds to the shape of each concave strip on the top surface of a corrugated steel sheet for an automobile passenger compartment. and a cylindrical flat roll, the sheet-like floor covering material is rolled into a uniform sheet with a width and protrusion dimension that corresponds to the shape of each concave strip on the upper surface of the corrugated steel sheet and approximately matches the width and depth of the concave strip. A third step of forming the bed sheet into a floor covering having a convex portion consisting of a convex strip or a plurality of small convex stripes or an aggregate of small convexities, and supplying it onto a cooling conveyor, (d) Forming supplied onto the cooling conveyor The fourth step is to cool down the floor covering, transfer it to a cutting table, and cut it into products. 2. A method for manufacturing a plastic floor covering for an automobile cabin according to claim 1, wherein the skin material is adhered to the flat side of the molded floor covering on the surface of the mold roll by pressing with a rubber roll. . 3. The automobile cabin according to claim 1, wherein the skin material is supplied from the flat roll side, and the floor covering material is formed by the flat roll and the mold roll, and is simultaneously attached to the flat side of the floor covering. A method of manufacturing a plastic floor covering. 4. The method of manufacturing a plastic floor covering for an automobile cabin according to claim 1, wherein a skin material is attached to the flat side of the cut floor covering in the fourth step.