JP2003291711A - Floor mat and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat capable of preventing permeation, passage and pollution of a vehicle body floor carpet floor surface by muddy water or the like so as to be widely used like a conventional floor mat, of securing good installation stability without impairing safe driving by forming slip-stopping projections, and of reducing noise in the vehicle interior. <P>SOLUTION: This floor mat 1 is composed by joining a carpet 2 to a back rubber sheet 3 on the back surface of the carpet 2. In the floor mat 1, the rubber sheet 3 is formed of a rubber foam containing continuous air bubbles as main constituents, the rubber foam has a density of 0.6-1.2 g/cm<SP>3</SP>, and the rubber sheet 3 has air permeability. <P>COPYRIGHT: (C)2004,JPO

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 a carpet and a back rubber sheet on the back surface of the carpet, and a method for producing such a floor mat.

[0002]

2. Description of the Related Art Conventional products (1) Floors of desired shape made of rubber or thermoplastic elastomer with various decorative engraving patterns on the surface and anti-slip engraving patterns or protrusions on the back surface. The mat is manufactured in a pressed shape and widely used.

Conventional Product (2) FIG. 9 is a sectional view of a part of a conventional floor mat 51 of this example. A back rubber sheet 53 made of rubber or a thermoplastic elastomer is cut on the back surface of the surface carpet 52 by various laminating methods or laminating molding methods to cut a laminate into a desired shape, and the periphery of the cut material is sewn by sewing machine or the like. Floor mat 5 having a decorative peripheral portion 56 shaped by the decorative method
1 is the most widely used. In FIG. 9, the carpet is made up of raised hairs 52a and base cloth 52b, and the back rubber sheet 53 is provided with anti-slip projections 53a.

Since the surface of the floor mat according to the conventional product (2) is a carpet, the appearance is beautiful and the touch is good.
It is widely used because muddy sand, dust, etc. are trapped inside the brushed carpet and do not easily spill outside, and dirt is not noticeable.

Further, in the floor mat according to the conventional product (2), even if muddy water penetrates the carpet surface, muddy water does not penetrate below the laminated rubber or the back rubber sheet layer of the thermoplastic elastomer. , Plays an important role not to pollute the interior carpet of the car body.

Further, since the floor mat according to the conventional product (2) has many anti-slip projections on the entire back surface of the back rubber sheet, the anti-slip projections are provided on the floor surface of the floor interior carpet of the vehicle body. Slip-in is prevented, slippage is prevented, stability is maintained, and safe driving is ensured. As described above, the conventional product (2) has been widely put to practical use for a long time because it sufficiently satisfies many of the requirements required for the floor mat.

Conventional product (3) Japanese Patent Application Laid-Open No. 2001-47926 describes a piece mat for an automobile having a low density, multi-void sound absorbing material attached to the back surface. In the detailed description of the invention, a backing layer is conventionally formed of a non-water-permeable material in order to prevent dirt such as mud from penetrating into a floor carpet (carpet of a vehicle body) in an automobile piece mat. However, it is disadvantageous in quieting the passenger compartment, and the sound reflection from the conventional backing raises the noise level in the passenger compartment, and the protrusions for preventing misalignment also create gaps that help the intrusion of noise. In such an automobile piece mat, the configuration of the conventional product (2) described above is denied.

[0008]

The floor mat of the conventional product (1) is in great demand in the future because of its simple structure and low cost, and the fact that it can be easily taken out of the vehicle and washed by washing with water and drying it. I think that the. The floor mat of the conventional product (2) is considered to be used as a main force of the floor mat because it has many useful and excellent properties as described above.

However, the floor mat of the conventional product (1) is
Since the sound transmission loss (dB) is large, the effect of preventing sound from entering under the floor due to the sound insulation effect can be expected to be a little, but because of the rubber material for the noise that has entered the vehicle interior, the sound is largely reflected and absorbed. Since the effect is small, the effect of preventing noise cannot be expected. In the floor mat of the conventional product (2), the original carpet itself has an excellent sound absorption coefficient because it has a raised structure with long porosity. Since the sound transmission loss (dB) is large and the sound reflection is large, there is a problem that the sound absorption coefficient is remarkably lowered and the noise prevention effect is hindered.

The conventional product (3), which is found in the patent publication, is a low-density, multi-void material, which is a so-called sound absorbing material, attached to the back surface of the carpet. The sound insulation is low and only absorbs the noise in the passenger compartment. Moreover, this product has a high water absorption and a large water content, so that the permeation and permeation of sewage is rapid, so that the floor carpet of the vehicle body is likely to be contaminated.

An object of the present invention is to prevent the penetration, passage and contamination of the floor surface of the vehicle body floor carpet due to muddy water, etc., as well as being widely used like conventional floor mats, and to provide a non-slip projection. In addition to ensuring that the mat is stable and not hindering safe driving, it is necessary to obtain a floor mat that can reduce noise in the passenger compartment.

[0012]

SUMMARY OF THE INVENTION The present invention is a floor mat in which a carpet and a back rubber sheet on the back surface of the carpet are joined, wherein the back rubber sheet comprises a rubber foam mainly composed of open cells. According to the floor mat, the rubber foam has a density of 0.6 to 1.2 g / cm ³ , and the back rubber sheet has air permeability.

Further, according to the present invention, in obtaining a floor mat in which a carpet and a back rubber sheet on the back surface of the carpet are crushed, (1) a foamable sheet shape laminated on the back surface of the carpet and the carpet. A step of producing a laminated body to be treated containing unvulcanized rubber, (2) a step of disposing the laminated body to be treated in a molding die, (3)
The mold for the carpet side of the laminated object is 20 to 1
A temperature of 20 ° C., and a temperature of the die on the sheet-shaped unvulcanized rubber side of 120 to 180 ° C., (4) the laminated object to be treated is 589 kPa or less (= 6 kgf / cm ² or less, 1 kgf / cm ² = converted by 98.0665 kPa) and pressurizing and heating with a lamination surface pressure, and (5) vulcanizing the sheet-shaped unvulcanized rubber to generate continuous cells and the back rubber sheet. And a step of joining the back rubber sheet and the carpet at the same time when the floor mat is formed.

As a result of various studies for solving the above-mentioned problems, the present inventor has found that the back rubber sheet on the back surface of the carpet has a density of 0.6 to 6 mainly composed of fine open cells.
By using 1.2 g / cm ³ of rubber foam,
It has been found that a floor mat having excellent soundproofing properties can be obtained while retaining the conventional advantages.

According to the present invention, a rubber foam having a predetermined density, which is mainly composed of open cells for a floor mat, suppresses the permeation of muddy water and the like, and sufficiently exerts the sound absorption characteristics on the front surface side and the sound insulation characteristics on the back surface side. It is based on the knowledge that it is possible.

The present inventor has also found that the floor mat can be integrally molded at the same time by press-vulcanizing a predetermined object to be processed.

According to the present invention, a floor mat made of a carpet and a back rubber sheet made of a given rubber foam on the back side of the carpet is provided with a laminated object to be treated made of a given carpet and a sheet-like unvulcanizable rubber. It is based on the finding that they can be integrally molded at the same time by applying pressure and heating.

The back rubber sheet according to the present invention comprises a rubber foam mainly composed of open cells.
It has a density and air permeability of 0.6 to 1.2 g / cm ³ .

In the present invention, such a back rubber sheet serves as a sound insulation material made of rubber and has a function of isolating and reducing noise from the vehicle body which is about to enter from the back surface of the floor mat. On the other hand, in the present invention, since the back rubber sheet is made of the rubber foam mainly composed of the open cells, noise from the vehicle body can enter the rubber foam by the open cells, and the noise is attenuated by the open cells. Also, noise is efficiently reduced by sound absorption by the carpet of the floor mat.

Further, in the present invention, since the back rubber sheet is made of a rubber foam mainly composed of open cells, it also serves to reduce the intrusion noise from the surface of the floor mat.
In the present invention, the sound once entering the vehicle interior and reflected in the vehicle interior is absorbed by the carpet of the floor mat and the back rubber sheet made of rubber foam mainly composed of open cells.

According to the floor mat of the present invention, since the back rubber sheet is made of a rubber foam mainly composed of predetermined open cells, the front and back surfaces of the floor mat exhibit remarkably high sound absorption characteristics and noise into the vehicle interior. While preventing the intrusion of
It is possible to effectively reduce noise in the vehicle interior.

Further, according to the floor mat manufacturing method of the present invention, the floor mat having the above-mentioned extremely high sound absorbing characteristics can be integrally molded at the same time by a predetermined press vulcanization molding.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing a form seen from the upper surface of a floor mat according to an example of the present invention. Figure 2
(A) is sectional drawing of a part of floor mat of an example of this invention, (b) is an expanded sectional view of a back rubber sheet. FIG. 3 is a sectional view of a part of a floor mat according to another example of the present invention.

FIG. 4 is a graph showing the sound absorption coefficient of various materials and laminates constituting the floor mat. FIG. 5 is a graph of the sound absorption coefficient measured by adding felt to the sound absorption coefficient measurement sample of FIG. FIG. 6 is a graph showing the measurement results of the transmission loss (dB) when the sound is made incident from the back rubber sheet surface.

FIG. 7 is a cross-sectional view showing a charged state of the material immediately before vulcanization molding by the vulcanization molding press of an example of the present invention. FIG. 8 is a cross-sectional view showing a charged state of the material just before vulcanization molding by the vulcanization molding press of another example of the present invention.

(1) Floor Mat FIGS. 1 and 2 show a floor mat 1 according to an example of the present invention. The floor mat 1 includes a carpet 2 and a predetermined back rubber sheet 3 provided on the back surface of the carpet 2. There is.
The back rubber sheet 3 is made of a rubber foam mainly composed of open cells 4, the rubber foam has a density of 0.6 to 1.2 g / cm ³ , and the back rubber sheet 3 has air permeability.

FIG. 3 shows a floor mat 11 according to another example of the present invention.
1 and 2 is different from the floor mat 1 shown in FIGS. 1 and 2 in that a nonwoven fabric layer 15 is provided between the carpet 12 and the back rubber sheet 13, and the other is the back rubber sheet 1.
Similar to floor mat 1, such as 3 having open cells.

In FIGS. 1 to 3, the carpets 2 and 12 are shown.
Is a brushed carpet 2 on the front side of the floor mats 1 and 11.
a, 12a and carpet base cloths 2b, 12b on the back rubber sheets 3, 13 side.

Such a floor mat is laid and used, and has a function of being taken out of the room and easily cleaned or replaced in order to prevent the floor surface of the interior of the automobile, etc. from being contaminated by mud and dust.

The present invention relates to a floor mat capable of reducing the noise in the passenger compartment, which has recently been particularly desired, without impairing the above-mentioned function of preventing pollution, and a method for manufacturing the floor mat.

FIGS. 4 and 5 show the results of measuring the sound absorption coefficient of the material of the present invention and the laminate of the material, and FIG. 6 shows the sound transmission loss (d) of the back rubber sheet.
B) is shown and is a reference material for judging the improvement of the noise prevention ability of the floor mat.

As shown in FIGS. 4 and 5, the carpet alone has a high sound absorption coefficient, but the sound absorption coefficient is significantly reduced in the sample in which the solid rubber sheet is laminated on the carpet. Further, the sound absorption coefficient is improved in a sample in which a foam rubber sheet mainly composed of open cells is laminated on this carpet.

Further, as shown in FIG. 6, since the solid rubber back rubber sheet has a large sound transmission loss (dB), it has a large sound reflectance and is good as a sound insulating material. But,
It is considered that when these are laminated, the reflectance is large and the sound absorption of the surface carpet is greatly reduced.

On the other hand, since the open-cell backing rubber sheet has a small sound transmission loss (dB) and a low sound reflectance as shown in FIG. 6, a floor mat using this is a solid backing rubber sheet. Compared with, it is possible to greatly reduce the decrease in the sound absorption coefficient of the surface carpet surface.

The floor mat of the present invention, as shown in FIG. 6, is formed by laminating a back rubber sheet made of a rubber foam mainly composed of open cells on the back surface of the carpet.
It seems that it has the ability to block some noise that enters from under the floor of the car.

Further, the floor mat of the present invention is considered to be a sound insulating material which is superior to the value of the transmission loss (dB) shown in FIG. 6 by making the open cells of the rubber foam into fine open cells. Such floor mats are shown in FIGS.
As shown in, it is considered that it is effective for noise reduction as well as sound insulation while suppressing reflection of noise in the vehicle interior. Noise reductions have also been confirmed in actual ride tests.

From these results, it can be seen that the floor mat 1 shown in FIGS. 1 and 2 exhibits a good sound absorption coefficient and a good sound insulation property. Therefore, when the floor mat 1 is laid on the floor surface in the vehicle compartment, noise is efficiently absorbed and reduced.

Further, as shown in FIGS. 4 and 5, the sample in which a non-woven fabric (felt) was added and laminated between the carpet and the foamed rubber sheet showed a very excellent sound absorption coefficient.

From this, the floor mat 11 laminated by adding the non-woven fabric layer 15 as shown in FIG. 3 has a very excellent sound absorption coefficient and absorbs noise when laid on the floor surface in the passenger compartment. It turns out that it remarkably reduces.

As shown in FIGS. 4 and 5, comparing the sound absorption coefficient measurement results, in particular, as shown in FIG. 5, three felts having good air permeability and a high sound absorption coefficient were layered on top of each other, and the sample was sampled. The sound absorption rate is higher when the measurement is performed by installing.

This means that the carpet having a good sound absorption coefficient is also installed on the floor surface in the passenger compartment at the time of manufacturing the vehicle. Therefore, if a floor mat having a good sound absorbing effect is laid on the carpet, the carpet shown in FIGS. As can be seen, it has an excellent sound absorption coefficient and absorbs noise well, and a noise prevention effect can be expected.

From the measurement results of FIGS. 4 and 5, the carpet alone or the carpet and the non-woven fabric (felt) or the carpet and the so-called sound absorbing material and the low-density, multi-void cotton material (glass wool, rock wool, etc.) are laminated. When a floor mat without a back rubber sheet or a foam back rubber sheet is analogized, a very excellent sound absorbing effect is expected.

However, this one has a weak waist and is easily wrinkled in the passenger compartment, and the anti-slip projections 3a and 13a as shown in FIGS. 2 and 3 are not provided. There is a problem with sex.

The carpet alone or a laminate of carpet and non-woven fabric (felt) or only carpet and sound absorbing material has high water absorption, high water absorption, high air permeability, and when water is encountered, water is immediately passed through the vehicle. There is a fatal drawback that the carpet installed on the indoor body is flooded and contaminated. Such a floor mat deviates from the general required function of the floor mat that has been widely used in the past.

In order to eliminate such a defect, as shown in FIG. 9, in the conventional floor mat 51, a solid back rubber sheet 53 is laminated, but in the present invention, it is shown in FIGS.
The problems and drawbacks described above are overcome by laminating the back rubber sheets 3 and 13 of a rubber foam having air permeability and mainly composed of the open cells 4 shown in FIG.

The solid backing rubber sheet used in conventional floor mats has a density of 1.2 to 1.45 g / cm ³ . In the floor mat of the present invention, rather than solid rubber, a relatively high density of 0.6 to 1.2 g / cm ³ foamed to generate open cells at a foaming ratio of 1.2 to 2.0 times is used. Since the back rubber sheet made of the rubber foam is used, water does not easily penetrate into the open cells of the back rubber sheet due to the surface tension of water, and the carpet floor surface of the car body is not contaminated by dirty water or the like.

In order to increase the sound absorption coefficient, the floor mat made of a low-density, multi-gap sound-absorbing material such as cotton is lightweight and has no slippage effect, and thus has no position stability and hinders safe driving. is there. In the floor mat of the present invention, since the backing rubber sheet having a relatively high volume density is used, the slip resistance is easy to work and the positional stability is high. In particular, as shown in FIGS. 2 and 3, the floor mats 1 and 11 provided with anti-slip protrusions 3a and 13a similar to the anti-slip protrusions 53a of the conventional floor mat 51 of FIG. You can walk and drive easily.

(2) Carpet The carpet according to the present invention can be produced by using a product made of at least one fiber selected from the group consisting of natural fibers and synthetic fibers. In addition, various woven fabrics are used, but a backing treatment of synthetic rubber latex or the like on the back surface of a synthetic fiber duffed carpet or needle punched carpet is most widely used in terms of appearance, function, and cost.

(3) Back Rubber Sheet The back rubber sheet according to the present invention is made of a rubber foam mainly composed of open cells. The back rubber sheet can be made of various materials and shapes, and can be manufactured by various methods.

(3-1) Rubber Foam The rubber foam according to the present invention can be made of various materials and shapes, and is not particularly limited as long as it is made of rubber foamed by an appropriate means. It can be manufactured by various methods without using.

As the raw material rubber of the rubber foam, at least one kind of rubber selected from the group consisting of natural rubber, synthetic rubber, regenerated rubber and the like can be used.

In the present invention, such a rubber foam is obtained by adding a foaming agent such as a vulcanizing agent, a vulcanization accelerating agent, a vulcanization accelerating aid, an antiaging agent, a reinforcing agent, a filler, a softening agent to the above-mentioned raw material rubber. It is possible to prepare a foaming aid and other rubber chemicals by blending them according to the required function and using a foamable unvulcanized rubber composed of a mixed rubber composition.

(3-2) Open Cell The rubber foam according to the present invention is mainly composed of open cells. The rubber foam mainly composed of open cells can be produced by various methods without particular limitation.

In the present invention, the open cells are preferably fine open cells that allow a gas such as air to pass through but not a liquid such as water. Here, the fine open cells are open cells formed in the rubber foam, and are open cells that allow gas such as air to pass through but not liquid such as water.

The open cells of the rubber foam do not allow liquids such as water to pass therethrough, prevent muddy water from entering the carpet, and maintain the laying stability of the floor mat.

The rubber foam mainly composed of such open cells can be obtained by carrying out vulcanization molding while foaming an unvulcanizable rubber which is capable of being foamed while being pressurized and heated at a low pressure.

In particular, according to the above method, it is possible to obtain a rubber foam which is fine and has air permeability mainly composed of open cells. Since the bubbles of this product are minute, it is possible to prevent the muddy water from penetrating into the lower layer by blocking the passage of water by the surface tension of water.

(3-3) Density The rubber foam according to the present invention has a density of 0.6 to 1.2 g / cm ^3.
Has a density of. The density of the rubber foam depends on the density of the unvulcanized rubber before foaming and has a correlation with the foaming ratio.

The rubber foam having a density of 0.6 to 1.2 g / cm ³ has the above-mentioned good sound absorbing property. With a rubber foam obtained by foaming a predetermined rubber, it is difficult to produce a rubber foam outside the range of the density.

(3-4) Expansion Ratio The density of the rubber foam is correlated with the expansion ratio. 0.6 g
Density rubber foam of / cm ³ can be obtained and foaming unvulcanized rubber density of about 1.2 g / cm ³ to about 2.0 times of expansion ratio, of 1.2 g / cm ³ A rubber foam having a density can be obtained by foaming unvulcanized rubber having a density of about 1.45 g / cm ³ about 1.2 times.

(3-5) Breathability The back rubber sheet according to the present invention has breathability. Such air permeability is due to the open cells of the rubber foam, and the sound absorbing performance of the floor mat is sufficiently exerted by such air permeability.

(3-6) Water Impermeable The back rubber sheet according to the present invention is preferably water impermeable. Such a back rubber sheet can be made of a rubber foam mainly composed of fine open cells that allow a gas such as air to pass therethrough but does not allow a liquid such as water to pass therethrough.

Since such a back rubber sheet is made of a rubber foam mainly composed of open cells, it is considered that water may enter the open cells due to water pressure or treading pressure. Must be water permeable.

(4) Nonwoven fabric layer In the present invention, it is preferable to laminate a nonwoven fabric layer between the carpet and the back rubber sheet. Such a nonwoven fabric layer can further improve the sound absorption coefficient of the floor mat due to the air layer formed by the nonwoven fabric.

The non-woven fabric is not particularly limited, and any one made of at least one fiber selected from the group consisting of natural fibers, synthetic fibers, glass wool, rock wool and the like can be used. In addition, these recycled fibers are also used. In general, it is preferable that the sound absorption characteristics have a sense of volume. The use is selected in combination with the carpet in terms of cost and sound absorption requirements.

The nonwoven fabric layer according to the present invention is preferably formed of a bulky nonwoven fabric. In the present invention, the bulky nonwoven fabric refers to a nonwoven fabric having a thickness of 2 mm or more. It should be noted that the thicker the bulky nonwoven fabric, the better the sound absorption because the air retention amount can be secured.
It is preferably 0 mm or less. Here, the thickness of the bulky nonwoven fabric refers to a value when a load of 10 g per 1 cm ² is applied.

The areal density of such a bulky non-woven fabric layer is 200 to 1000 g so as to contribute to the weight reduction of an automobile mat.
/ M ² is preferred. The apparent density (area density divided by thickness) of the bulky nonwoven fabric layer is 0.01 to 0.5 g.
/ Cm ³ is preferable.

Such a bulky nonwoven fabric has, for example, (1)
After forming the fibrous web by the dry method, needle punching is performed (2) to form the fibrous web containing the heat-fusible fiber by the dry method, and then under no pressure or under a weak pressure for adjusting the thickness. By applying heat to melt the heat-fusible fibers, or (3) fineness 6.6 dt
It can be manufactured by laminating melt blown nonwoven fabrics of ex or more.

The fibers constituting this bulky nonwoven fabric are not particularly limited, but examples thereof include natural fibers, organic synthetic fibers, and inorganic fibers.

(5) Anti-slip projections In the present invention, when a rubber foam is manufactured, it is integrally formed at the same time.
Non-slip protrusions 3a, 13a as shown in FIGS. 2 and 3 can be formed. Such a non-slip protrusion enables a floor mat having a good laid stability.

As shown in FIGS. 4 and 5, the floor mat of the present invention is replaced with a conventional solid back rubber sheet, and has 0.6 to 1.2 g / cm 2 containing mainly open cells.
By using a breathable back rubber sheet made of a rubber foam having a density of ^3, the front surface side has excellent sound absorption characteristics, and the back surface side has sound absorption characteristics and sound insulation characteristics.

(6) Method for Manufacturing Floor Mat The floor mat of the present invention uses a predetermined rubber foam mainly composed of open cells as a breathable back rubber sheet.
For this reason, when an adhesive is applied to the back rubber sheet and dried, since the back rubber sheet is a high-density rubber, there is a high possibility that open cells will be covered with the coating film of the adhesive and lose air permeability. Therefore, in the floor mat manufacturing method of the present invention, the laminating method using an adhesive is inappropriate.

In the present invention, in the floor mat, foaming, joining and vulcanization molding of the back rubber sheet can be simultaneously performed integrally. This floor mat is manufactured by a method according to the method described in Japanese Patent Publication No. 63-47611, which will be described in detail below, so that the raised hair of the carpet does not cause compressive strain due to heating and pressurization. To manufacture.

To produce the floor mat of the present invention, during press vulcanization molding, a laminate to be treated in which a predetermined foamable sheet-form unvulcanized rubber is superposed on the back surface of the carpet, or the carpet and sheet-form. Either one of the laminated objects to which the non-woven fabric layer is added in the middle of the unvulcanized rubber is placed in the press vulcanization molding machine, and the surface of the carpet is 20 to 120 ° C
At the temperature of 120 from the unvulcanized rubber sheet that can be foamed
At a temperature of ˜180 ° C., each is subjected to pressurization and heating for a required time at a lamination surface pressure of 6 kgf / cm ² (about 589 kPa) or less, and foaming, lamination and vulcanization molding are simultaneously performed integrally,
A floor mat with good sound absorption can be obtained.

Another method of manufacturing the floor mat is a laminate to be treated in which a predetermined foamable sheet-like unvulcanized rubber is superposed on the back surface of the carpet during press vulcanization molding, or the carpet. A sheet capable of being foamed at a temperature of 20 to 120 ° C. from the carpet surface side by arranging either of the laminated objects to be processed, in which a nonwoven fabric layer is added between the sheet-like unvulcanized rubber and the sheet-like unvulcanized rubber, in the press vulcanization molding machine. From the unvulcanized rubber side at a temperature of 120 to 180 ° C, 6 to 50 kg of each at the beginning of the step of pressurizing and heating to vulcanize and mold.
After a short-time pressurization with a lamination surface pressure of f / cm ² (about 589 kPa to about 4.91 MPa) once or a plurality of times, a lamination surface pressure of 6 kgf / cm ² (about 589 kPa) or less is required. It is possible to pressurize and heat for a period of time to perform foaming and laminated vulcanization molding integrally at the same time to obtain a floor mat having good sound absorption.

The above-mentioned two production methods by press vulcanization molding (claims 4 to 6) are the production methods according to the production method of laminated products in Japanese Patent Publication No. 63-47611. Press laminating vulcanization molding method in which the temperature of the carpet surface is lowered to a low temperature at which the raised hair of the carpet is not heat-compressed with respect to the vulcanization temperature required for vulcanizing the sheet, and the laminating molding pressure of both is extremely low. In this way, the raised floor of the carpet is less likely to be thermally compressed (permanent set), and the floor mat can be produced without impairing the appearance of the carpet.

According to the present invention, since the production method according to the present invention is carried out at an extremely low pressure of laminating molding in which the bubbles generated by foaming are not compressed again by the high pressure of laminating molding to become a bubble-free solid rubber, It is the basis for the production of floor mats having a foamed back rubber sheet that mainly has open cells and has air permeability.

(6-1) Floor Mat According to the method of the present invention, a floor mat including a carpet and a back rubber sheet on the back surface of the carpet can be obtained.

(6-2) Laminated object to be processed According to the method of the present invention, a laminated object to be processed including a carpet and a foamable sheet-shaped unvulcanized rubber laminated on the back surface of the carpet is prepared.

The carpet is not particularly limited, and the carpet formed of various fibers as described above can be used.

(6-3) Foamable sheet-shaped unvulcanized rubber In the method of the present invention, foaming is performed so that open cells are generated when the foamable sheet-shaped unvulcanized rubber is pressed and heated. Let

Such a sheet-form unvulcanizable rubber capable of foaming is
It can be produced using various raw materials. For example, the above-mentioned raw material rubber and rubber composition can be used.

In the present invention, the sheet-like shape means a shape required for producing a laminated object to be laminated and pressed and heated on a carpet, and the thickness, size, shape and the like are not particularly limited. An appropriate shape may be formed as the back rubber sheet of the floor mat. For example, a sheet having a thickness of 1.5 mm obtained by rolling with a calendar roll machine is used.

(6-4) Mold for molding In the method of the present invention, the above-mentioned laminated object to be processed is placed in the mold for molding. As the molding die, if the floor mat can be formed by pressurizing and heating the laminated object,
There is no particular limitation, and various devices can be used.

In the present invention, the vulcanization molding dies 7 and 17 and the vulcanization forming press 8 having the configurations shown in FIGS.
18 can be used.

Lower molds 7b, 1 for vulcanization molds 7, 17
7b are lower molds 7b and 17b in which recesses for forming a large number of anti-slip projections 3a and 13a are formed on the back surfaces of the foamed back rubber sheets 3 and 13, and are described in FIGS. 7 and 8. Omitted.

(6-2) Pressurization and Heating In the floor mat manufacturing method of the present invention, the laminated object is pressed and heated for a predetermined time. The pressurization and heating are processes for joining the laminated objects to be processed, vulcanizing and foaming the unvulcanized rubber.

(6-3) Temperature In the heat treatment according to the present invention, the temperature of the carpet side of the laminated object is 20 to 120 ° C, and the temperature of the sheet-shaped unvulcanized rubber side is 120 to 180 ° C. Within these temperature ranges, the back rubber sheet can be molded without impairing the texture of the carpet, and a good floor mat can be manufactured.

(6-4) Pressure In the pressure treatment according to the present invention, the laminated object to be treated is 589 k
The pressure is applied at a lamination surface pressure of Pa or less, preferably 98.0 to 589 kPa. Within this pressure range, the back rubber sheet can be molded without impairing the texture of the carpet even if the laminated surface pressure is not, and a good floor mat can be manufactured.

(6-5) Generation of open cells In the method of the present invention, the sheet-shaped unvulcanized rubber is vulcanized to form open cells. The open cells are preferably fine open cells that allow a gas such as air to pass through but not a liquid such as water.

Various conditions can be set for generating open cells in the sheet-shaped unvulcanized rubber, and are not particularly limited.

(6-6) Joining of Carpet and Back Rubber Sheet In the method of the present invention, the carpet and back rubber sheet are joined by pressurizing and heating the laminated object. At this time, the back rubber sheet has air permeability because it foams so as to generate open cells as described above.

(6-7) Pressurization and heating time In the method of the present invention, the pressing and heating time of the laminated object to be processed is set to the desired joining and molding of the object to be laminated and the desired unvulcanized sheet form. Various settings can be made to cause vulcanization, foaming and molding of rubber.

(6-8) Nonwoven Fabric Layer In the present invention, in the production of the laminated object to be processed in the first step,
A nonwoven layer can be added between the carpet and the sheet of unvulcanized rubber.

By treating the laminated object to which the non-woven fabric layer is added, a floor mat having a remarkably high sound absorbing performance in which the back rubber sheet, the non-woven fabric layer and the carpet are joined can be produced.

(6-9) Pre-pressurization In the method of the present invention, prior to the pressurization in the fourth step, the laminated object to be processed is subjected to 6-50 kgf / cm ² (about 589 kPa-
At least one pre-pressurization can be performed with a lamination surface pressure of about 4.91 MPa.

Such pre-pressurization is carried out even if the lamination surface pressure in the subsequent fourth step is 589 kPa or less, for example, even if the lamination surface pressure is no pressure.
The back rubber sheet can be molded without impairing the texture of the carpet, and a good floor mat can be manufactured. Further, such preliminary pressurization can be performed for a desired time.

(6-10) Anti-Slip Protrusions In the method of the present invention, anti-slip protrusions can be provided on the back rubber sheet by using a predetermined mold or the like at the same time as the floor mat is manufactured.

[0099]

The invention will be described in more detail on the basis of embodiments with reference to the drawings. Use nylon tufted carpet. The backing surface of this carpet is backed with a thin synthetic rubber latex. This carpet is cut into a shape slightly larger than the required shape, and the carpets 2 and 12 for the object to be processed as shown in FIGS. 7 and 8 are prepared.

A rubber composition prepared by blending the above-mentioned raw rubber and rubber chemicals according to the required functions, in particular fine air-permeable cells mainly composed of continuous cells, with a foaming ratio of 1.2 to 2.0. The compounding ratio of the rubber composition, which is doubled, is kneaded, rolled into a sheet of 1.5 mm with a calender roll, and this sheet is cut into a shape slightly larger than the required shape, as shown in FIGS. 7 and 8. Prepare and prepare the unvulcanized back rubber sheets 3b, 13b capable of forming fine fine continuous cells.

On an infrared heating conveyor, a 0.1 mm hot melt film was superposed on a 5 mm-thick bulky nonwoven fabric (cotton felt) surface and heated continuously,
After applying a slight pressure to lightly stack the two, the felt is prepared and cut into a shape slightly larger than the shape of the key portion.

Example 1 Using the press machine 8 for vulcanization molding shown in FIG. 7, cooling water was introduced from the cooling water inlet 8f so as to keep the upper heating plate 8a always at 50 to 60 ° C. and the cooled water outlet. 8 g of the upper mold 7a is circulated by discharging the upper mold 7a with the heat insulating material 8c.
Adjust to maintain 0-60 ° C. The lower heating plate 8b introduces the heating steam into the heating steam inlet 8d to drain the drain water 8e.
Then, the steam pressure is adjusted so as to be maintained at 150 ° C. and the lower metal plate 7b is maintained at 150 ° C. by using the heat insulating material 8c.

On the lower mold 7b, the carpet 2 prepared as described above and the foamable unvulcanized back rubber sheet 3b prepared as described above are arranged in an overlapping manner as shown in FIG. Then, the press machine 8 for vulcanization molding is closed, and pressurization and heating are performed for 6 minutes at a pressure at which the lamination surface pressure becomes 2 kgf / cm ² (about 196 kPa), and foaming / lamination / vulcanization molding is performed. Then, the vulcanization press 8 is opened and the molded product is taken out.

This is cut again into an accurate required shape, and its peripheral portion is sewn with an overlock sewing machine to decorate the peripheral portion 6.
If the floor mat 1 is provided, the floor mat 1 shown in FIG. 1 having a cross section shown in FIG. 2 can be manufactured.

Example 2 Using the vulcanization molding press 18 shown in FIG. 8, cooling water was introduced from the cooling water inlet 18f so as to keep the upper heating plate 18a at 30 to 60 ° C. and the cooled water outlet 18g. It is circulated after being discharged from and is adjusted using the heat insulating material 18c. The lower hot platen 1
In 8b, heated steam is introduced into the heated steam inlet 18d and discharged from the drain water outlet 18e, and the heat insulating material 18c is used to
Keep the temperature at 0 ℃ and lower mold 17b attached to this at 150 ℃
Adjust with steam pressure to keep.

The foamable unvulcanized back rubber sheet 13b prepared as described above was placed on the lower mold 17b, and the felt hot melt film surface prepared as described above was faced upward on the lower mold 17b. Place them on top of each other,
Further, the carpet 12 prepared in the above is placed on the carpet 12 with the carpet brush 12a facing upwards, and the vulcanization press 18 is closed and tightened to open the valve of the air inlet 17d. Mold 17
2kgf / cm ² (about 19
(6 kPa) for 6 minutes under pressure and heating to perform foaming, lamination, and vulcanization molding at the same time, then close the valve of the air inlet 17d and open the valve of the air outlet 17e to discharge the air. The press for vulcanization molding 8 is opened and the molded product is taken out. Note that the bulky nonwoven fabric is omitted in FIG. 8.

Next, this is cut again into an accurate required shape and the peripheral edge portion is provided with a decorative peripheral edge 16 by sewing with an overlock sewing machine, and the nonwoven fabric layer 1 shown in the cross section of FIG.
A floor mat 11 having the number 5 as shown in FIG. 1 can be manufactured.

The main reason why floor mats that are laid in the vehicle compartment have been widely used for many years is that they can be easily taken out of the vehicle compartment and cleaned, and that the interior of the vehicle can be kept clean and that the lining material is A rubber sheet prevents permeation of dirty water, does not contaminate the carpet floor surface of the car body, and has good stability in laying.

In the floor mat of the present invention, the back rubber sheet is made of a rubber foam mainly composed of predetermined open cells.
While retaining the above-mentioned conventional advantages, the front and back surfaces of the floor mat exhibit extremely high sound absorption characteristics,
It is possible to prevent noise from entering the vehicle interior and efficiently reduce the noise inside the vehicle interior.

[0110]

INDUSTRIAL APPLICABILITY The floor mat according to the present invention is a floor mat in which a back rubber sheet to be laminated on a carpet is laminated with a foamed back rubber sheet having mainly air bubbles and having air permeability to improve sound absorption. for,
Placing this on the floor in the passenger compartment has the effect of reducing noise in the passenger compartment.

Among the floor mats of the present invention, a nonwoven fabric (felt) is provided between the carpet and the foamed back rubber sheet.
The floor mat formed by laminating and adding the layers has a significantly improved sound absorption coefficient. Therefore, when the floor mat is laid on the floor surface in the vehicle compartment, the noise in the vehicle compartment is greatly reduced.

In the floor mat according to the present invention, the heating temperature from the carpet surface is extremely low and / or the carpet and the foamed back rubber sheet are laminated by a vulcanization press, and the molding pressure is extremely low. Laminated by an ordinary press machine, which is not found in a vulcanization molded article, has an effect of obtaining a floor mat having a good appearance with a slight permanent set due to thermal compression of carpet raising.

In the production method of the present invention, the carpet and the foamed back rubber sheet, and the non-woven fabric (felt) layer and the like in between, are foamed / laminated (non-slip protrusions) using a press for vulcanization molding. Since the vulcanization molding is simultaneously performed integrally, there is an effect that the floor mat can be efficiently manufactured with a small number of manufacturing steps and a small number of steps.

[Brief description of drawings]

FIG. 1 is a perspective view showing a form of a floor mat according to an example of the present invention.

FIG. 2A is a sectional view of a part of a floor mat of an example of the present invention, and FIG. 2B is an enlarged sectional view of a back rubber sheet.

FIG. 3 is a sectional view of a part of a floor mat according to another example of the present invention.

FIG. 4 is a graph showing the sound absorption coefficient of an example material according to the present invention.

FIG. 5 is a graph showing sound absorption coefficients of materials of other examples according to the present invention.

FIG. 6 is a graph showing sound transmission loss (dB) of an example material according to the present invention.

FIG. 7 is a cross-sectional view showing a charged state immediately before vulcanization molding by a vulcanization molding press according to an example of the present invention.

FIG. 8 is a cross-sectional view showing a charged state immediately before vulcanization molding by a vulcanization molding press according to another example of the present invention.

FIG. 9 is a sectional view of a part of a conventional floor mat.

[Explanation of symbols]

1,11 floor mat 2,12 carpet 2a, 12a Brushed carpet 2b, 12b Carpet base cloth 3,13 Foam back rubber sheet 3a, 13a Foam back rubber non-slip protrusion 3b, 13b Unvulcanizable back rubber sheet that can be foamed 4 open cells 15 Nonwoven fabric (felt) layer 6,16 Decorative edge 7,17 Vulcanization mold 7a, 17a Upper mold 7b, 17b Lower mold 7c air bag 7d air inlet 7e Air outlet 8,18 Vulcanization press machine 8a, 18a Upper heating plate 8b, 18b Lower heating plate 8c, 18c insulation 8e, 18e drain water outlet 8f, 18f Cooling water inlet 8g, 18g Cooled water outlet

Front page continuation (51) Int.Cl. ⁷ Identification code FI theme code (reference) B32B 25/10 B32B 25/10 31/20 31/20 // B29K 21:00 B29K 21:00 B29L 9:00 B29L 9 : 00 31:58 31:58 (72) Inventor Sakae Nakasuji 4-1-11 Katsube, Moriyama-shi, Shiga Japan F-term inside Shiga factory of Japan Vileen Co., Ltd. (reference) 3B088 FA01 FA02 FB04 FB05 FC01 HA01 3B120 AA01 AA04 AA14 AA28 AB18 AB19 AB20 BA02 BA03 BA21 BA28 BA38 EA10 EB01 EB11 EB21 EB22 4F100 AN00B BA02 BA03 BA10A BA10B DD01B DG15C DG16A DJ01B EJ202 EJ422 GB33 GB81 JA13B JD02B JH01 JK16B YY00B 4F211 AA45 AD08 AD16 AD17 AD20 AE06 AG02 AG03 AG20 AH26 TA09 TC02 TD11 TH06 TH10 TN84 TN87 TQ04

Claims (6)

[Claims] 1. A floor mat in which a carpet and a back rubber sheet on the back surface of the carpet are joined, wherein the back rubber sheet is made of a rubber foam mainly composed of open cells, and the rubber foam is 0. A floor mat having a density of 0.6 to 1.2 g / cm ³ and the back rubber sheet having air permeability. 2. The floor mat according to claim 1, wherein a slip prevention protrusion is provided on the back surface of the back rubber sheet. 3. The floor mat according to claim 1, wherein a nonwoven fabric layer is provided between the carpet and the back rubber sheet. 4. When obtaining a floor mat in which a carpet and a back rubber sheet on the back surface of the carpet are joined, (1) a carpet and a foamable sheet-like unvulcanized rubber laminated on the back surface of the carpet. And (2) arranging the laminated body to be processed in a molding die, (3) forming the laminated body to be processed on the carpet side of the laminated body.
A temperature of 0 to 120 ° C., and a temperature of the die on the sheet-shaped unvulcanized rubber side to 120 to 180 ° C., (4) pressurizing the laminate to be treated with a laminate surface pressure of 589 kPa or less, and A heating step; and (5) a step of vulcanizing the sheet-shaped unvulcanized rubber to generate continuous cells to form the back rubber sheet and, at the same time, joining the back rubber sheet and the carpet. The method of manufacturing a floor mat. 5. In the step (1), the non-woven fabric layer is added between the carpet and the sheet-shaped unvulcanized rubber to produce the laminated object, and in the step (5), the back rubber sheet is used. The method for manufacturing a floor mat according to claim 4, wherein the non-woven fabric layer and the carpet are joined together. 6. The floor mat according to claim 4 or 5, wherein prior to the step (4), the laminate to be processed is pre-pressurized at least once with a laminate surface pressure of 589 kPa to 4.91 MPa. Manufacturing method.