JP2002306312A - Floor mat and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor mat which is hardly shifted regardless of a kind of a floor face, is excellent in non-slip effect to prevent a person from stumbling and slipping, and can be lightened, and a manufacturing method thereof. SOLUTION: A mat substrate 2, a heated thermoplastic resin sheet member 3 as a middle layer, and a sheet shape foam body 4 are supplied in between an embossing roll with a number of recess parts for forming projections 7 and a receiver roll so that the foam body 4 is in contact with the embossing roll and pressed and adhered to form a number of projections 1 projected into the foam body 4. Because the projections 7 grip the floor face and, further, the foam body 4 with uneven foam traces is in contact with the floor face, a lightened floor mat 1 with excellent non-slip performance, waterproof performance, and soundproof performance can be effectively manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor mat provided with anti-slip means for use around a seat of a vehicle, an entrance of a house, a kitchen, a bathroom, and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In general, floor mats are spread on seat floors such as a driver's seat of a vehicle, and entrances of houses and the like in order to wipe off dirt and mud attached to anti-slip and shoes, and kitchens. Floor mats are also placed on bathrooms and bathrooms to prevent slippage, absorb moisture, and prevent dirt. In such a floor mat, for example, a non-slip member such as rubber having an uneven shape is usually provided on the back surface of the carpet-shaped mat substrate so that the floor mat does not shift. Also, in order to give the floor mat an appropriate hardness and increase the strength, a synthetic resin layer is provided on the back surface of the mat base material. A device such as attaching a non-slip member having an engaging piece formed of a projection planted thereon has been devised.

[0003]

However, in a floor mat in which only a non-slip member such as rubber is provided on the back surface of the mat base material, for example, in the case of a smooth floor made of synthetic resin,
When stepping on such a way that a large load acts locally, the mat is likely to slip, and the strength of the mat is insufficient. Particularly in the case of a vehicle, a complicated force is applied to the mat surface when getting on and off. Acts, so that the mat substrate is easily damaged.

On the other hand, in a method in which a synthetic resin layer is provided on the back surface of a mat base material, and a non-slip member in which the engaging pieces are implanted is adhered to the synthetic resin layer, it takes time to implant and adhere these members. It costs. In addition, when the mat is laid on a carpet that has been installed in advance such as a vehicle, for example, the engaging piece cuts into the surface, and an anti-slip effect is obtained.
In the case of a hard floor surface, such as a synthetic resin floor or a flooring floor, the engaging pieces do not cut into the floor surface, and only the anti-slip effect of the base cloth is obtained. It was not enough to prevent it.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a floor mat which is less likely to slip and has an excellent non-slip effect capable of preventing dangers such as slipping or stumbling, regardless of the type of floor surface, and which can be reduced in weight and a method of manufacturing the same. To provide.

[0006]

In order to solve the above-mentioned problems, the present invention employs the following configuration.

That is, a thermoplastic sheet member and a sheet-like foam are laminated on the lower surface side of the mat base material so that the sheet member becomes an intermediate layer. The floor mat was formed by integrally providing a number of protrusions protruding from the floor mat.

In this way, when the user steps on the mat,
The protrusions and the foam are pressed against the floor surface, and a large gravity acts locally on each protrusion as compared with a case where the lower surface of the mat is flat, so that a frictional force is generated at a contact point between the protrusion and the floor surface. The mat becomes large, and the projections grip the floor, so that the non-slip property of the mat is improved.

In addition, like the projections, traces of air bubbles on the surface of the foam which come into contact with the floor surface like the projections dig into the unevenness of the floor surface, and this foam contributes to improvement of non-slip property.

The soundproofing and vibration damping effects can be obtained by the synergistic action of the thermoplastic sheet member laminated in the middle of the mat and the foam. Further, by the sheet member,
A waterproof effect is also obtained, and a high-grade feeling is obtained by the foam with a moderate cushioning property. The foam has a low density even if the thickness has a certain volume feeling so that an appropriate cushioning property can be obtained, so that the weight can be reduced as compared with a conventional mat having the same thickness.

The thermoplastic sheet member includes:
A thermoplastic resin, a thermoplastic elastomer, rubber, or the like can be used. Further, as the sheet-like foam, a foam of a synthetic resin can be used.

The mat member, the heated thermoplastic sheet member and the sheet-like foam are placed between an embossing roll provided with a number of concave portions for forming projections and a receiving roll. As an intermediate layer, the foam is supplied so as to be in contact with an embossing roll, and pressure-bonded, and a protrusion is formed on the thermoplastic sheet member to project into the foam, whereby a floor mat can be manufactured. .

[0013] According to this structure, the embossing roll can simultaneously bond the thermoplastic sheet member to the mat base material and the sheet-like foam and form the projections, thereby improving adhesion and non-slip properties. An excellent floor mat can be efficiently manufactured.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS.

A floor mat 1 according to the embodiment of the present invention shown in FIG. 1 includes a carpet-like mat base material 2 and a sheet material 3 of a thermoplastic material, that is, an intermediate layer of a thermoplastic resin.
And a sheet-like foam 4 of polyurethane.
The mat substrate 2 has a base fabric 5 on which pile yarns 6 are implanted, and a plurality of projections 7 are integrally formed on the lower surface of the sheet member 3 by projecting into the foam 4. The member 3 is joined to the mat base 2 and the foam 4.

As the thermoplastic resin, an olefin resin such as polyethylene or polypropylene, a styrene resin such as polystyrene, a mixed resin thereof, or a vinyl chloride resin can be used.

The shape of the projections 7 may be any of a conical shape, a spherical shape, a circular cross section, an elliptical shape, a triangular shape, a quadrangular shape, a polygonal shape, a shape having a tip portion sucked or branched. The height is desirably about 1 to 5 mm. In addition, these projections 7 may be provided in any of a discrete form as shown in FIG. 1A or a continuous form in a rib shape, and may be made of synthetic resin, fiber, flooring, or the like. Depending on the type of the floor surface, etc., as shown by the dashed line in FIG. 1B, the foam 4 can be formed at a position similar to or below the lower surface of the foam 4. The distance between these projections is 3 mm to 50 m when provided in a discrete form or when provided in a continuous form like a rib.
The range of m is desirable.

The mat base material 2 may be any of those having pile yarns implanted on a base cloth, such as tufted carpets, and those having no pile yarns implanted on a base cloth, such as needle punch carpets. , Felt, woven fabric and the like can be used.

As the thermoplastic sheet member 3, besides the above-mentioned thermoplastic resin, a thermoplastic elastomer such as polyolefin or polystyrene, a general-purpose rubber such as styrene-butadiene rubber, or a special rubber such as ethylene-propylene rubber. Can be used.

Further, a foaming agent may be blended in advance with these thermoplastic resin, thermoplastic elastomer and rubber, and the sheet member 3 may be foamed and provided between the mat base material 2 and the foam 4. . In this case, the expansion ratio is 1.1 to
About three times is desirable.

Further, an antibacterial sheet member 3 in which an antibacterial agent containing a metal such as silver as an antibacterial component is added to the above-mentioned thermoplastic resin, thermoplastic elastomer, and rubber, is used between the mat substrate 2 and the foam 4. Can also be provided.

As the foam 4, a foam of a synthetic resin such as polyethylene, polypropylene and polyester can be used in addition to polyurethane. The range of the thickness of the foam 4 is preferably 1 to 10 mm, and the expansion ratio is desirably 5 to 100 times. The type of cells may be either closed cells or open cells. An appropriate thickness and expansion ratio can be selected in consideration of the fit.

The sheet member 3 and the foam 4
Can be colored to any color by using a coloring agent.

FIGS. 2 and 3 show an apparatus for manufacturing the floor mat 1. The apparatus for manufacturing the floor mat 1 includes, as an example, a projection 7 formed on the lower surface of the sheet member 3.
An embossing roll 9 having a large number of cylindrical recesses 8 having a diameter of 2 mm and a depth of 2 mm provided at a center interval of 5 mm, and a flat roll receiving roll 10 are vertically assembled in a roll housing (not shown). Molding machine and an extrusion molding machine 1 arranged on the entrance side thereof and having a sheet mold 11 attached thereto.
2 is provided. The embossing roll 9 is rotatably supported by a supporting member 13 with a roll neck 9a, and a pressing cylinder 14 is attached to the supporting member 13 to apply a pressing force. The embossing roll 9 is internally water-cooled in order to prevent overheating due to repeated filling of the recess 8 with the sheet member 3a. Similarly, the receiving roll 10 is rotatably supported at its roll neck 10a by a support member (not shown).
These rolls 9 and 10 are driven by a motor (not shown) via a speed reducer and the like.

The pressure cylinder 14 may be provided on the receiving roll 10, or the embossing roll 9 may be disposed on the lower side and the receiving roll 10 may be disposed on the upper side.

The extruder 12 has, for example,
50% styrene resin and 3% olefin resin
A material containing 0%, 18% of calcium carbonate as a filler, and 2% of a coloring agent is supplied from the inlet 15 and is stirred at a molding temperature of about 200 ° C. while being stirred and mixed by a screw provided in a heating cylinder. Then, the mixture is heated and melted, extruded into the sheet mold 11 by the screw, and cooled and solidified to continuously obtain a thermoplastic resin sheet member 3a having a thickness of about 1.3 mm as an example. Then, the carpet-shaped mat base material 2a wound on the reel 16 is wound on the reel 16a on the surface of the sheet member 3a on the side of the receiving roll 10 via the roller 17 as an example. Between the embossing roll 9 and the receiving roll 10 of the press molding machine, a sheet-like polyurethane foam 4a having a foaming ratio of 5 mm and an expansion ratio of about 70 times overlaps the surface of the sheet member 3a on the side of the embossing roll 9 respectively. And pressurized by the pressurizing cylinder 14 at a pressure of about 0.4 MPa, for example, at a roll peripheral speed of the rolls 9 and 10 of about 3 m / min. At this time, the thermoplastic resin sheet member 3a in a heated state while retaining the amount of heat at the time of molding is compressed into a foam 4a compressed by pressure.
Through the recess 8 provided in the embossing roll 9 so as to be filled, and a large number of cylindrical projections 7 having a diameter of 2 mm and a height of 2 mm are integrally formed on the surface of the sheet member 3a with a center interval of 5 mm. You. A laminate 1a in which an intermediate layer sheet member 3a having a thickness of about 1 mm is formed between the mat base material 2a and the foam 4a by the formation of the projections 7 is formed into an emboss roll 9 and a receiving roll 10. The foam 4 once discharged is elastically restored to the original thickness of 3.5 mm, is cooled by contact with a cooling roll (not shown), and is not shown via the roller 17a. It is wound by a winder. Thus, the floor mat 1 is formed.

The embodiment of the present invention is configured as described above, and its function will be described below.

When the floor mat 1 is stepped on, the projections 7 and the foam 4 are pressed against the floor surface, and a large gravity acts locally on each projection 7. The frictional force increases, and the protrusion 7 grips the floor surface, and the non-slip property of the mat 1 is improved.

Also, like the protrusions 7, the traces of air bubbles on the surface of the foam 4 which is in contact with the floor surface like the projections 7 bite into the unevenness of the floor surface, so that the foam 4 contributes to the improvement of the non-slip property.

The floor mat 1 has a waterproof property due to the thermoplastic resin sheet member 3 of the bonded intermediate layer, and has an appropriate cushioning property due to the foam 4 and has a sense of quality.

In order to obtain an appropriate cushioning property, the foam 4 has a low density even if the thickness has a certain volume feeling so that the weight can be reduced as compared with a conventional floor mat having the same thickness. Can be. Since the foam 4 exists between the projections 7, even when the projections 7 are formed to project from the lower surface of the foam 4, the floor mat 1
The protrusion height of the projection 7 on the lower surface of the substrate is extremely small, which makes it easy to handle, and is also preferable in terms of design.

Further, the synergy between the thermoplastic resin sheet member 3 and the foam 4 laminated in the middle of the floor mat 1 provides a soundproofing and vibration damping effect. Further, by using the foamed sheet member 3, its flexibility is increased, which contributes to the improvement of the gripping property of the projections 7 on the floor surface, the soundproofing property and the vibration damping property, and further reduces the weight. For vehicles, it also contributes to improved fuel efficiency. In addition, excellent non-slip properties are exhibited regardless of the type of floor surface, that is, the hardness of the floor surface.

As described above, the mat base material 2a and the foam 4a are laminated on both surfaces of the heated thermoplastic resin sheet member 3a having a calorie at the time of molding and extruded from the extrusion molding machine 12. Since the pressure is applied by the embossing roll 9, the projections on the sheet member 3a and the bonding between the mat base material 2a and the foam 4a can be simultaneously and reliably performed, and the adhesion and the non-slip properties are excellent. Floor mat 1 can be manufactured efficiently.

FIG. 4 shows an apparatus for manufacturing a floor mat 1 according to another embodiment. An embossing roll 9 provided with a large number of concave portions 8 for forming projections, similar to that shown in FIG. On the input side of the pressure molding machine comprising the receiving roll 10,
A heat drum 18 for heating the sheet member 3a;
A contact roll 19 is provided. This heat drum 18
Is heated to about 80 ° C. to 150 ° C. by an electric heater 21 attached to the heat retaining covers 20 and 20a.
The heating of the heat drum 18 can also be performed using steam or a gas burner.

The sheet member 3a wound on the reel 16b
While being supported by the contact roll 19, it contacts the outer peripheral surface of the heat drum 18 and is heated to a temperature at which plasticity is obtained. As in the case shown in FIG. 2, the sheet member 3a is wound between the mat base material 2a wound on the reel 16 and having the joint surface heated by the heater 22 and the foam 4a wound on the reel 16a. Is supplied between the embossing roll 9 and the receiving roll 10 of the pressure molding machine, and is pressure-bonded between the mat base material 2a and the foam 4a. At this time, the sheet member 3a penetrates the foam 4a and flows into the concave portion 8 to be filled, and the protrusion is formed integrally.
Then, the laminate 1a in which the sheet member 3a of the intermediate layer is joined between the mat base material 2a and the foam 4a is discharged from between the embossing roll 9 and the receiving roll 10, and the cooling rolls 23, 23a And is wound up by a winder (not shown). Even in this manner, the floor mat 1 can be formed.

It should be noted that the sheet member 3b wound on the reel 16c is superimposed on the sheet member 3a, heated by the heat drum 18, and supplied to the pressure molding machine as described above, whereby the intermediate layer is formed of a plurality of layers. It can also be formed by a sheet member.

[0037]

As described above, according to the present invention, a synthetic resin sheet member provided with a number of projections is joined between a mat base material on the upper surface side and a sheet-like foam on the lower surface side. Since these protrusions protrude into the foam to form the floor mat, the protrusions grip the floor surface,
In addition, foam with irregular air bubble traces on the surface also comes into contact with the floor surface, and regardless of the type of floor surface, it can exhibit excellent non-slip properties.For example, in a running vehicle, due to the displacement of the mat during driving It is possible to prevent dangers such as an operation error and a stumbling upon getting on and off.

Also, it has excellent waterproof, soundproof and vibration damping properties,
Reduces discomfort such as noise and vibrations from the feet of a running vehicle, etc., and has a moderate cushioning, so it has a high-class feel.Moreover, since the foam has a low density, the thickness of the foam is increased to increase the volume. Even if it is put out, it can be reduced in weight and has excellent handleability.

Further, since the sheet member of the intermediate layer is pressure-bonded to the mat base material and the foam by the pressure molding machine, a projection is formed on the lower surface of the sheet member so as to project into the foam. Also, a floor mat excellent in non-slip properties can be efficiently manufactured.

[Brief description of the drawings]

FIG. 1A is a partially cutaway perspective view of a floor mat according to an embodiment of the present invention viewed from the lower surface side. FIG.

FIG. 2 is a side view showing the manufacturing apparatus according to the first embodiment;

FIG. 3 is an enlarged side view showing a main part of FIG. 2;

FIG. 4 is a side view showing a floor mat manufacturing apparatus according to another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Floor mat 1a Laminated body 2, 2a Mat base material 3, 3a, 3b Sheet member 4, 4a Foam 5 Base cloth 6 Pile thread 7 Projection 8 Depression 9 Emboss roll 9a Roll neck 10 Receiving roll 10a Roll neck 11 For sheet Mold 12 Extrusion molding machine 13 Support member 14 Pressure cylinder 15 Input port 16, 16a, 16b, 16c Reel 17, 17a Roller 18 Heat roll 19 Contact roll 20, 20a Heat retaining cover 21 Electric heater 22 Heater 23, 23a Cooling roll

Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat II (Reference) // A47L 23/22 A47L 23/22 F B29K 105: 04 B29K 105: 04 B29L 7:00 B29L 7:00 9:00 9:00 31:58 31:58 (72) Inventor Naoko Yubara 95-1 Nagoso, Konoguchi-cho, Ito-gun, Wakayama Prefecture F-term in Koei Chemical Industry Co., Ltd. 3B088 FA02 FB05 FC01 3B120 AA24 AB04 DA11 EA01 EA03 EA04 EA10 EB21 4F209 AA04 AA11 AA24 AA42 AD05 AD08 AD35 AG01 AG03 AG06 AG20 AH26 AH49 PA04 PB02 PC05 PH03 PH06 PJ01 PN06 PN20 4F211 AA04 AA11 AA13 AA42 AD16 AD17 AG28 AH26 AH51 TA08 TC02 TD

Claims (2)

[Claims] 1. A thermoplastic sheet member and a sheet-like foam are laminated on the lower surface side of a mat base material such that the sheet member becomes an intermediate layer, and the thermoplastic sheet member and the foam are laminated on the thermoplastic sheet member. A floor mat with a large number of protrusions that protrude integrally. 2. A mat base material, a heated thermoplastic sheet member, and a sheet-like foam are placed between an embossing roll provided with a number of concave portions for forming projections and a receiving roll. A method of manufacturing a floor mat in which a sheet member is used as an intermediate layer, the foam is supplied so as to be in contact with an embossing roll, and pressure-bonded, and a projection is formed on the thermoplastic sheet member to project into the foam.