JP2007126084A - Floor mat and floor structure using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat capable of being stably installed on an installation face so as to prevent its slip and having superior sound absorbing performance, and to provide a floor structure using the mat. <P>SOLUTION: On this floor mat 1 provided with a surface fiber layer 2 made of textiles and a rear surface soft layer 3 made of a soft material, a plurality of through holes 25 passing through an upper face and a lower face and a plurality of column-like parts 20 provided with shaft parts 21 having the same cross section from a lower face to a predetermined position in the vicinity of a tip are provided and arranged on the rear surface soft layer 3 at a predetermined pattern when viewing the rear surface soft layer 3 from above or below. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention mainly relates to a floor mat for installation on a vehicle floor material of an automobile, and a floor structure using the floor mat.

  Generally, a vehicle floor material is composed of a plurality of layers, and the uppermost layer is a floor carpet layer for making up the surface on the vehicle interior side. The floor carpet layer is composed of a base fabric and napping raised from the surface of the base fabric, and in particular, a tufted carpet or a needle punch carpet is widely used.

  In general, a floor mat is laid on the floor carpet layer for the purpose of preventing the floor carpet layer from being soiled or improving the design of the vehicle interior. As such a car floor mat, a conventional product (1) shown in FIG. 12, a conventional product (2) shown in FIG. 13, and the like are known.

  As shown in FIG. 12, the conventional product (1) 101 includes a front carpet layer 102 and a back rubber layer 103, and a number of anti-slip protrusions 104 are provided on the bottom surface of the back rubber layer 103. The anti-slip protrusion 104 has a substantially conical shape in which the diameter of the cross section decreases toward the tip, and enters between the raised portions 122 of the floor carpet layer 121 from the tip having a relatively small diameter to the base end having a relatively large diameter. It has come to enter smoothly. In this way, the slip prevention protrusion 104 enters the floor carpet layer 121, thereby preventing the floor mat 101 from sliding on the floor carpet layer 121.

On the other hand, the conventional product (2) 111 has a sound absorbing material layer 113 made of felt laminated on the back side of the surface carpet layer 112, as shown in FIG. In the conventional product (2) 111, a part of the sound incident from the surface side (vehicle compartment side) can be absorbed by the sound absorbing material layer 113. In addition, the structure which laminates | stacks a sound-absorbing material layer on the back side of a surface carpet layer is disclosed by patent document 1, for example.
JP 2004-198611 A

  By the way, if a space layer having a predetermined height or more is formed between the upper surface of the floor carpet layer and the lower surface of the floor mat, it is possible to effectively absorb sound in the space layer. In other words, the sound that has entered the surface of the floor mat from the passenger compartment and reaches the space layer is repeatedly reflected irregularly on the upper surface of the floor carpet layer and the lower surface of the floor mat, and is attenuated each time it is reflected. be able to.

  In this regard, the conventional product (1) 101 shown in FIG. 12 is provided with the anti-slip protrusion 104 on the bottom surface of the back rubber layer 103, so that the above-described space layer is formed by the height of the anti-slip protrusion 104. It can be thought of as possible. However, since the anti-slip protrusion 104 enters the entire floor carpet layer 121 as described above, the conventional product (1) 101 is difficult to form a space layer and effectively absorbs sound. Is not something you can do.

  Further, the back rubber layer 103 in the conventional product (1) 101 is made of solid rubber or thermoplastic elastomer and has no air permeability. Therefore, since the sound incident from the front surface side of the conventional product (1) 101 is reflected by the back rubber layer 103 and cannot be absorbed by the conventional product (1) 101 or the vehicle floor material 120, the quietness in the vehicle interior is obstructed. Resulting in.

  On the other hand, although the conventional product (2) 111 shown in FIG. 13 includes the sound absorbing material layer 113, the sound absorbing effect by the sound absorbing material layer 113 cannot be obtained yet. Moreover, since the conventional product (2) 111 is installed in a state where the entire lower surface thereof is in contact with the upper surface of the floor carpet layer 121, it is not possible to improve the sound absorption performance by forming a space layer as described above. Furthermore, since the conventional product (2) 111 does not include the anti-slip projection 104 unlike the conventional product (1) 101, the conventional product (2) 111 cannot be stably installed so as not to slip on the installation surface. Driving safety may deteriorate.

  Accordingly, an object of the present invention is to provide a floor mat that can be stably installed so as not to slip with respect to the installation surface, and has an excellent sound absorbing performance, and a floor structure using the floor mat. .

In order to solve the above problems, a floor mat according to claim 1 of the present invention is provided.
In what has a surface fiber layer and a back surface soft layer made of a soft material,
The back soft layer is
A plurality of through-holes that pass through the upper and lower surfaces of the back soft layer and are arranged in a predetermined pattern when the back soft layer is viewed from above or below;
A shaft portion extending downward from the lower surface and having the same cross section from the lower surface to a predetermined position near the tip is provided, and is arranged in a predetermined pattern when the back soft layer is viewed from above or below. A plurality of columnar portions.

  In the floor mat according to claim 2 of the present invention, the back soft layer has an inclined surface that surrounds the lower surface openings of the plurality of through-holes and spreads in a mortar shape outward from the through-holes in the radial direction. It is characterized by.

  In the floor mat according to claim 3 of the present invention, the plurality of columnar portions includes a first columnar portion having a predetermined length in the vertical direction, and a second column having a shorter length than the first columnar portion. The first columnar part and the second columnar part are arranged in a predetermined pattern when the back soft layer is viewed from above or below, including a columnar part.

  In the floor mat according to claim 4 of the present invention, the diameter of the columnar part is 2 to 6 mm, and the length of the columnar part is 2 to 6 mm.

  The floor mat according to a fifth aspect of the present invention is characterized in that the length of the shaft portion in the columnar portion is 1 to 3.5 mm.

  The floor mat according to claim 6 of the present invention is characterized in that the columnar portions are arranged in a lattice form with an interval of 5 to 20 mm when the back surface soft layer is viewed from above or below. And

  The floor mat according to a seventh aspect of the present invention is characterized in that an opening ratio of the through holes is 2 to 20%. Here, the open area ratio of the through holes is defined by the ratio of the total area of the open holes of the through holes to the area of the back surface soft layer.

  The floor mat according to an eighth aspect of the present invention is characterized in that the thickness of the back soft layer is 0.5 to 2 mm.

Floor mat according to claim 9 of the present invention, the surface fiber layer, and a brushed rising from the base fabric and the base fabric, the basis weight of the surface fiber layer is 500~3000g / m ^2, the surface The raised height in the fiber layer is 3 to 20 mm.

  The floor mat according to claim 10 of the present invention is characterized in that a sound-absorbing material layer having air permeability is interposed between the front surface fiber layer and the back surface soft layer.

The floor mat according to an eleventh aspect of the present invention is characterized in that the basis weight of the sound absorbing material layer is 100 to 1000 g / m ² and the thickness of the sound absorbing material layer is 1 to 10 mm.

A floor mat according to a twelfth aspect of the present invention is characterized in that the opening ratio of the through hole is β (%), the length of the shaft portion is α (mm), and the thickness of the back surface soft layer is γ (mm). When each is done, the following relational expression is satisfied.

  In the floor structure according to claim 13 of the present invention, a floor fiber layer is disposed under the back soft layer in the floor mat, and a space layer is formed between the upper surface of the floor fiber layer and the lower surface of the back soft layer. It is characterized by being.

  The floor structure according to claim 14 of the present invention is characterized in that the floor fiber layer is provided with a base fabric and napping raised from the surface of the base fabric, and the length of the napping is 0.5 to 3 mm. To do.

  According to the present invention, the columnar portion of the back surface soft layer includes a shaft portion having the same cross section from the bottom surface of the back surface soft layer to a predetermined position in the vicinity of the tip, and is disposed on the lower side of the floor mat. Since the shape does not penetrate deeply into the fiber layer, a space layer having a desired height can be formed between the upper surface of the floor fiber layer and the lower surface of the back surface soft layer. The sound that reaches the space layer repeats irregular reflection on the upper surface of the floor fiber layer and the lower surface of the back soft layer, and attenuates each time it is reflected. Can be improved.

  Moreover, since the back surface soft layer has air permeability ensured by a plurality of through holes arranged in a predetermined pattern, the sound absorbing function of the space layer formed below the back surface soft layer, and the space layer further It is possible to prevent the sound absorbing function of the lower floor material from being hindered.

  In particular, by providing a mortar-shaped inclined surface surrounding the lower surface opening of the through hole on the back soft layer, the sound that repeats reflection as described above is reflected on the inclined surface so as not to come out of the through hole again. be able to. Therefore, the reflection of the sound described above can be sufficiently repeated to sufficiently attenuate the sound, and the sound absorption effect in the space layer can be further enhanced.

  In addition, the columnar part of the back soft layer has the function of preventing the floor mat from sliding on the installation surface, as with the conventional anti-slip protrusion, so that it can be installed stably so that it does not slide on the installation surface. can do.

  1 to 3 show a floor mat 1 according to a first embodiment of the present invention. As shown in FIG. 1, the floor mat 1 is laid on a vehicle floor material 30 attached in advance to the floor of an automobile.

  The vehicle floor material 30 includes a plurality of layers, and the uppermost layer is a floor fiber layer 31. The vehicle floor material 30 includes one or more layers other than the floor fiber layer 31, but the type of the layer is not particularly limited. The layers other than the floor fiber layer 31 provided on the vehicle floor material 30 include, for example, a thermoplastic resin layer that contributes to the molding of the vehicle floor material 30, a sound absorbing material layer having a sound absorbing function, and a sound insulating function having a sound insulating function. A material layer etc. are mentioned.

  As shown in FIG. 2, the floor fiber layer 31 includes a base fabric 32 and raised hairs 33 rising from the surface of the base fabric 32. The height of the raising 33 is 0.5-3 mm. As the material of the floor fiber layer 31, at least one kind of fiber is used, and at least one of natural fiber and synthetic fiber is used. As the floor fiber layer 31, various woven fabrics and the like are used, and in particular, a tufted carpet or a needle punch carpet is preferably used.

  The floor mat 1 includes a surface fiber layer 2 made of woven fabric or the like and a back surface soft layer 3 made of a soft material. Further, a sound absorbing material layer 4 having air permeability is interposed between the front surface fiber layer 2 and the back surface soft layer 3.

  The surface fiber layer 2 includes a base fabric 11 and raised hairs 12 rising from the base fabric 11. As the material of the surface fiber layer 2, at least one kind of fiber is used, and at least one of natural fiber and synthetic fiber is used. The type of fiber in the surface fiber layer 2 is not particularly limited as long as it has air permeability.

  Various fabrics and the like are used as the material of the surface fiber layer 2, but a tufted carpet or a needle punch carpet is preferably used from the viewpoints of appearance, function, cost, and the like. When using a tufted carpet or a needle punch carpet, those made of synthetic fiber and thinly backed with a synthetic rubber latex or the like on the back surface are particularly preferably used.

Basis weight of the surface fiber layer 2 is preferably set to 500~3000g / ^{m 2,} it is optimal to 3000 g / ^{m 2.} The height of the raised hair 12 in the surface fiber layer 2 is preferably 3 to 20 mm, and most preferably 20 mm.

  As a material of the back surface soft layer 3, for example, solid rubber or rubber foam is used. As a raw material for the back surface soft layer 3, a raw rubber such as natural rubber, synthetic rubber, or recycled rubber is used. Further, the back surface soft layer 3 may be added to the raw rubber as required by a vulcanizing agent, a vulcanization accelerator, a vulcanization acceleration aid, an anti-aging agent, a reinforcing agent, a filler, a softening agent, a foaming agent, and a foaming aid. It is manufactured by blending an agent and other rubber chemicals. However, it does not prevent the use of a soft material other than rubber as the material of the back surface soft layer 3, and for example, a thermoplastic elastomer may be used.

The specific gravity of the back surface soft layer 3 is preferably 0.3 to 3.0 g / cm ^3, and the weight per unit area of the back surface soft layer 3 is optimally 1000 g / m ² . The thickness of the back soft layer 3 is preferably 0.5 to 2.0 mm, and most preferably 1.5 mm. The hardness of the back soft layer is preferably 40 to 85 in the JIS K 6253 standard (type A).

  The back surface soft layer 3 includes a plurality of columnar portions 20 arranged in a predetermined pattern when the back surface soft layer 3 is viewed from above or below. Specifically, when the back surface soft layer 3 is seen from the upper side or the lower side, the columnar portions 20 are arranged in a lattice pattern with a certain interval as shown in FIG. The interval between the axial centers of the adjacent columnar portions 20 is preferably 5 to 20 mm, for example, and optimally 15 mm. However, the columnar portions 20 are not necessarily arranged in the above pattern, and can be arranged in various patterns.

  These columnar portions 20 extend downward from the lower surface of the back surface soft layer 3 and have a shaft portion 21 having the same cross section from the lower surface to a predetermined position near the tip, and the diameter of the cross section decreases toward the tip. And a distal end portion 22.

  Specifically, the tip portion 22 of the columnar portion 20 is formed in a conical shape and smoothly enters between the raised portions 33 in the floor fiber layer 31. Therefore, in a state where the floor mat 1 is laid on the floor fiber layer 31, the floor mat 1 is reliably supported by the tip portion 22 of the columnar portion 20, and the floor mat 1 is prevented from sliding on the floor fiber layer 31. It can be done. The shape of the tip 22 is not particularly limited as long as the diameter of the cross section decreases toward the tip, and may be, for example, a polygonal pyramid.

  Specifically, the shaft portion 21 of the columnar portion 20 is formed in a columnar shape and does not easily enter between the raised portions 33 in the floor fiber layer 31. Therefore, in a state where the floor mat 1 is laid on the floor fiber layer 31, the shaft portion 21 of the columnar portion 20 protrudes upward from the upper end of the raised portions 33 of the floor fiber layer 31, and thus is disposed below the back surface soft layer 3. A space layer 29 is formed between the upper surface of the floor fiber layer 31 and the lower surface of the back surface soft layer 3. The shape of the shaft portion 21 is not particularly limited as long as it has the same cross section from the lower surface of the back surface soft layer 3 to a predetermined position near the tip, and may be, for example, a polygonal column shape.

  The diameter of the columnar portion 20 is preferably 2 to 6 mm, and most preferably 4 mm. Further, the length of the columnar portion 20 is preferably 2 to 6 mm, and most preferably 5 mm. Furthermore, the length of the shaft portion 21 of the columnar portion 20 is preferably 1 to 3.5 mm, and most preferably 3 mm.

  The back surface soft layer 3 includes a plurality of through holes 25 that penetrate the upper surface and the lower surface of the back surface soft layer 3 and are arranged in a predetermined pattern when the back surface soft layer 3 is viewed from above or below. Yes. Specifically, when the back surface soft layer 3 is viewed from the upper side or the lower side, the through holes 25 are arranged in a lattice pattern with a certain interval so as not to interfere with the columnar portion 20 as shown in FIG. Has been. The interval between the centers of the adjacent through holes 25 is set to be equal to the interval between the axial centers of the adjacent columnar portions 20. However, the through holes 25 are not necessarily arranged in the above-described pattern, and can be arranged in various patterns as long as they do not interfere with the columnar portion 20.

  By providing the through hole 25 in the back surface soft layer 3 in this way, the air permeability of the back surface soft layer 3 is ensured, and the sound incident from the surface of the floor mat 1 can pass through the back surface soft layer 3.

  The opening ratio of the through holes 25 (the ratio of the total area of the through holes 25 to the area of the back surface soft layer 3) is preferably 2 to 20%, and most preferably 10%. Thereby, favorable air permeability is obtained while ensuring the waterproof property of the floor mat 1.

これにより、空間層２９における後述の吸音機能を十分に発揮することができる。 Here, the opening ratio of the through hole 25, the length of the shaft portion 21, and the thickness of the back surface soft layer 3 are defined as β (%) for the opening ratio of the through hole 25 and α (mm for the length of the shaft portion 21. ) And the thickness of the back surface soft layer 3 is preferably set to satisfy the following relational expression (1), where γ (mm).

Thereby, the sound absorbing function described later in the space layer 29 can be sufficiently exhibited.

  Moreover, the back surface soft layer 3 has the inclined surface 26 which each encloses the lower surface opening part of the some through-hole 25, and spreads in a mortar shape toward the radial direction outer side from the through-hole 25. As shown in FIG. By providing the inclined surface 26, the sound that is about to enter the through hole 25 from the lower side of the back surface soft layer 3 is reflected by the inclined surface 26 and is difficult to enter the through hole 25.

The material of the sound absorbing material layer 4 is, for example, a nonwoven fabric, felt, or urethane foam, but is not particularly limited as long as it has air permeability. The basis weight of the sound absorbing material layer 4 is preferably 100 to 1000 g / m ² . The thickness of the sound absorbing material layer 4 is preferably 1 to 10 mm, and most preferably 10 mm.

  When the floor mat 1 having the above configuration is laid on the vehicle floor material 30, the sound incident from the surface of the floor mat 1 is absorbed by the sound absorbing material layer 4, and the sound that cannot be absorbed passes through the sound absorbing material layer 4. And reaches the back soft layer 3. The sound that has reached the back surface soft layer 3 passes through the through hole 25 and reaches the above-described space layer 29 and is absorbed by the space layer 29. That is, the sound that reaches the space layer 29 repeats irregular reflection on the upper surface of the floor fiber layer 31 and the lower surface of the back surface soft layer 3 and attenuates each time it is reflected, so that sound can be effectively absorbed in the space layer 29.

  In addition, since the sound that repeats such reflection is reflected by the inclined surface 26, it is difficult for the sound to come out from the space layer 29 through the through hole 25, so that the reflection of the sound described above is sufficiently repeated. Thus, the sound can be sufficiently attenuated, and the sound absorption effect in the space layer 29 is further enhanced.

  Further, in the state where the floor mat 1 is laid on the vehicle floor material 30, the end portion 22 of the columnar portion 20 enters the floor fiber layer 31 to reliably support the floor mat 1. 1 can be prevented from slipping on the vehicle floor material 30, and the safe driving of the automobile is not hindered.

  4 and 5 show a floor mat 41 according to the second embodiment of the present invention. In this embodiment, the back surface soft layer 3 includes a first columnar part 50 having a predetermined length in the vertical direction and a second columnar part 60 having a shorter length than the first columnar part 50, When the back surface soft layer 3 is viewed from above or below, the first columnar portion 50 and the second columnar portion 60 are arranged in a predetermined pattern.

  Specifically, as shown in FIG. 5, all the columnar portions 50, 60 are arranged in a lattice shape with a certain interval therebetween, and the first columnar portion 50 and the second columnar portion 60. Are arranged alternately in the horizontal direction and the vertical direction. However, the 1st columnar part 50 and the 2nd columnar part 60 can be arrange | positioned with various patterns besides the above.

  Since the second columnar section 60 is shorter than the first columnar section 50, as shown in FIG. 4, the floor mat 41 is supported only by the first columnar section 50, and the second columnar section 60 is a floor fiber. The floor mat 41 can be laid in a state of floating above the layer 31. In that case, the height of the space layer 29 can be secured relatively large.

  The second columnar portion 60 has a larger diameter than the first columnar portion 50, and the shaft portion 61 of the second columnar portion 60 is inserted between the raised portions 33 of the floor fiber layer 31. It is more difficult to enter than the shaft portion 51 of the columnar portion 50. Therefore, even if the gap between the raised portions 33 in the floor fiber layer 31 is large, and the shaft portion 51 of the first columnar portion 50 enters the gap, the shaft portion 61 of the second columnar portion 60 is the floor fiber layer. Therefore, the space layer 29 having a certain height can be secured.

  The diameter of the first columnar portion 50 is preferably 2 to 6 mm, and most preferably 4 mm. Further, the length of the first columnar portion 50 is preferably 2 to 6 mm, and most preferably 5 mm. Furthermore, the length of the shaft portion 51 in the first columnar portion 50 is preferably 1 to 3.5 mm, and most preferably 3.5 mm.

  The diameter of the second columnar portion 60 is preferably 4 to 8 mm, and most preferably 6 mm, within a range larger than the diameter of the first columnar portion 50. The length of the second columnar portion 60 is preferably 1 to 3 mm, and most preferably 2 mm, within a range shorter than that of the first columnar portion 50. Further, the length of the shaft portion 61 in the second columnar portion 60 is preferably 1 to 2 mm, and most preferably 2 mm, within a range shorter than the shaft portion 51 of the first columnar portion 50. is there.

  In the second embodiment, other configurations and effects are the same as those of the first embodiment. In FIGS. 4 and 5, members having the same functions as those of the first embodiment are denoted by the same reference numerals. It is.

  Next, a method for manufacturing the floor mats 1 and 41 will be described. However, the manufacturing method of the floor mats 1 and 41 is not necessarily limited to the following manufacturing method, and can be manufactured by various methods.

  In manufacturing the floor mats 1 and 41, vulcanization of the unvulcanized rubber sheet 66, which is the material of the back surface soft layer 3, molding of the back surface soft layer 3, and adhesion between the back surface soft layer 3 and the sound absorbing material layer 4 are performed simultaneously. For this purpose, a vulcanization press 68 shown in FIG. 6 is used. In addition, when using a foam as a raw material of the back surface soft layer 3, you may make it also foam the unvulcanized rubber sheet 66 simultaneously.

  The vulcanization press 68 includes an upper mold 70 and a lower mold 90. As shown in FIG. 7, a plurality of recesses 72 for forming columnar parts for molding the columnar parts 20 of the back surface soft layer 3 are provided on the lower surface of the upper mold 70. The upper mold 70 includes an upper layer 75 and a lower layer 76, and the columnar portion molding recess 72 is provided so as to penetrate the lower layer 76 of the upper mold 70 in the vertical direction. Thereby, when vulcanizing and molding the unvulcanized rubber sheet 66, even if gas is generated from the rubber chemical compounded in the unvulcanized rubber sheet 66, the gas does not accumulate in the recess 72 for columnar part molding. Therefore, molding defects can be prevented.

  Further, the upper mold 70 is provided with a pin 71 for forming a through hole of the back surface soft layer 3 so as to protrude downward. Thus, when the vulcanization molding press 68 is closed, the through-hole molding pin 71 penetrates the unvulcanized rubber sheet 66 and the through-hole 25 of the back surface soft layer 3 is molded. The through-hole molding pin 71 is preferably 4 to 10 mm so that the through-hole 25 can be opened reliably. Further, a concave portion 73 for molding an inclined surface is provided on the lower surface of the upper mold 70 so as to surround the pin 71 for molding the through hole.

  The lower mold 90 includes a spacer 92 that adjusts the gap between the upper mold 70 and the lower mold 90 when the vulcanization press 68 is closed. By adjusting the thickness of the spacer 92, it is possible to prevent the sound absorbing material 67 from being crushed by pressurization, and to control a weak pressure sufficient to mold the back surface soft layer 3.

  Further, on the upper surface of the lower mold 90, a pin avoiding recess 91 is provided corresponding to the position of the through hole molding pin 71 of the upper mold 70. Accordingly, when the vulcanization molding press 68 is closed, the through-hole molding pins 71 do not interfere with the lower mold 90.

  When using the press machine 68 for vulcanization molding, as a preparation, a rubber composition obtained by blending the raw rubber of the back surface soft layer 3 and a rubber chemical necessary for the required function is prepared. The back side soft layer 3 is obtained by kneading and rolling the kneaded rubber composition with a calender roll to a thickness of 0.5 to 2 mm and cutting the rubber composition to a size slightly larger than the floor mats 1 and 41. An unvulcanized rubber sheet 66 that is a material of the above is formed. Further, the sound absorbing material 67 which is a material of the sound absorbing material layer 4 is cut so as to have a size slightly larger than the floor mats 1 and 41.

  The press machine 68 for vulcanization molding is adjusted so that the temperature of the upper mold 70 is maintained at 150 to 180 ° C. and the temperature of the lower mold 90 is maintained at 40 to 60 ° C. The temperature adjustment of the upper mold 70 is performed at a temperature of 150 to 180 ° C. by constantly adjusting the press upper plate 80 according to the temperature and pressure of the steam introduced from the steam inlet 81 and discharged from the steam outlet 82 shown in FIG. It is done by adjusting so as to keep. The temperature of the lower mold 90 is adjusted so that the press lower plate 85 is always kept at 40 to 60 ° C. by circulating the cooling water introduced from the cooling water inlet 86 and discharged from the cooling water outlet 87 and the temperature of the heat insulating material 88. It is done by adjusting to.

  In this way, in a state where the temperature of the upper mold 70 and the lower mold 90 of the vulcanization press 68 is adjusted, the sound absorbing material 67 is placed on the lower mold 90, and the sound absorbing material 67 An unvulcanized rubber sheet 66 is placed thereon. And the vulcanization molding press 68 is closed, and pressurization and heating at a pressure of 589 kPa or less for 5 to 8 minutes, vulcanization of the unvulcanized rubber sheet 66, molding of the back surface soft layer 3, and The back surface soft layer 3 and the sound absorbing material layer 4 can be bonded simultaneously.

  Thereby, the back soft layer 3 and the sound absorbing material layer 4 are integrally molded, and the molded product is taken out by opening the vulcanization molding press 68. And the floor mats 1 and 41 can be manufactured by adhere | attaching the textile fabric etc. which are the raw material of the surface fiber layer 2 to the sound-absorbing material layer 4 in the taken-out molded article. Adhesion between the sound absorbing material layer 4 and the surface fiber layer 2 is performed by partial adhesion so as not to impair air permeability. For example, partial adhesion by a spider web-like hot melt, perforated hot melt, or an adhesive is used. Glue.

The sound absorption performance and anti-slip performance of the floor mat according to the present invention were confirmed by the following tests. The sample of the present invention is obtained by vulcanization molding of a sound absorbing material (thickness 5 mm, basis weight 500 g / m ² ) and an unvulcanized rubber sheet (thickness 1.5 mm, specific gravity 1.6 g / cm ³ ) by the above-described manufacturing method. The molded product obtained by molding with a press machine and a carpet (weight per unit area: 800 g / m ² , pile length: 8 mm) were bonded to each other. Further, the columnar portions of the back surface soft layer were formed so as to have a length of 5 mm and a diameter of 3 mm, and were arranged in a grid pattern with an interval of 10 mm. As a comparative example, samples of the conventional product (1) shown in FIG. 12 and the conventional product (2) shown in FIG. 13 were cut to an appropriate size.

(Sound absorption performance evaluation test)
In the test for confirming the sound absorption performance of the product of the present invention, the normal incident method sound absorption coefficient was measured according to JIS A1405 for the sample of the present product, the sample of the conventional product (1), and the sample of the conventional product (2). However, with regard to the product of the present invention, a plurality of samples having different through-hole ratios were prepared, and the sound absorption coefficient (%) was measured for each sample.

  FIG. 8 is a graph showing the sound absorption coefficient of the product of the present invention, the conventional product (1), and the conventional product (2) in which the opening ratio of the through holes is 10%. As shown in FIG. 8, it was confirmed that the conventional product (1) has a poor sound absorption coefficient in the entire frequency range, and the conventional product (2) has a high sound absorption coefficient in the frequency region of 1000 Hz or higher. On the other hand, the product of the present invention shows a better sound absorption rate than the conventional product (1) and the conventional product (2) in the entire frequency range. In particular, in the region of 2000 Hz or less, the sound absorption coefficient is significantly higher than that of the conventional product (1) and the conventional product (2). That is, it was confirmed that the product of the present invention has a large sound absorption effect in the human audible range generally called 20 to 2000 Hz.

  FIG. 9 is a graph showing the sound absorption rate of the product of the present invention and the conventional product (2) when the aperture ratio of the through holes is 0%, 2%, 5%, 10%, 15% and 20%. is there. As shown in FIG. 9, the product of the present invention when the hole area ratio is 10% shows the highest sound absorption coefficient in the entire frequency range. Subsequently, the sound absorption coefficient was high in the order of the present invention product with an opening rate of 15%, the present product with 5%, the present product with 20%, the present product with 2%, and the case where no through hole was provided ( The product of the present invention having an aperture ratio of 0%) and the conventional product (2) are almost the same in the entire frequency region and show the lowest sound absorption coefficient. From this, it was found that the sound absorption rate of the product of the present invention changes depending on the opening rate of the through holes, and it was confirmed that the highest sound absorbing effect was exhibited when the hole opening rate was 10%.

  FIG. 10 is a graph showing the sound absorption rate between the product of the present invention and the conventional product (2) when the through hole opening ratio is 4.5%, 10%, and 33%, and the relational expression (1 ) Satisfies the sound absorption effect. As described above, when the length α of the shaft portion is set to 1 to 3.5 mm and the thickness γ of the back surface soft layer is set to 0.5 to 2.0 mm, when applied to the relational expression (1), the through hole The opening ratio β of the following is 4.5 <β <33 (%). That is, it can be confirmed that the sound absorption coefficient of the present invention when the relational expression (1) is satisfied corresponds to the shaded portion in FIG. 10 and is higher than that of the conventional product (2) in a frequency region of 2000 Hz or less.

(Anti-slip performance evaluation test)
In the test for confirming the anti-slip performance of the product of the present invention, the slip resistance value (N) was measured for the sample of the present product, the sample of the conventional product (1), and the sample of the conventional product (2). In this test, a test piece obtained by cutting each sample into a size of 100 × 140 mm is placed on a vehicle floor material, and a load of 1 kgf (9.8 N) is applied to the test piece, and 100 mm / min. It was measured by pulling at a speed in a direction parallel to the surface of the vehicle floor material.

  FIG. 11 shows the slip resistance values of the product of the present invention, the conventional product (1), and the conventional product (2). As shown in FIG. 11, it was confirmed that the slip resistance value of the conventional product (2) was the lowest, and the slip resistance values of the product of the present invention and the conventional product (1) were almost equal and showed a high resistance value.

It is sectional drawing which shows the floor mat which concerns on the 1st Embodiment of this invention. It is the expanded sectional view similarly. It is the perspective view similarly seen from the lower surface side. It is sectional drawing which shows the floor mat which concerns on the 2nd Embodiment of this invention. It is the perspective view similarly seen from the lower surface side. It is sectional drawing which shows the press machine for vulcanization molding used for manufacture of a floor mat. It is the principal part expanded sectional view similarly. It is a figure which shows the sound absorption coefficient of the floor mat of this invention, the conventional product (1), and the conventional product (2). It is a figure which shows the change of the sound absorption rate by the aperture ratio of a through-hole. It is a figure which shows the sound absorption rate in case the aperture ratio of a through-hole is set so that a predetermined relational expression may be satisfied. It is a figure which shows the slip resistance value of the floor mat of this invention, a conventional product (1), and a conventional product (2). It is sectional drawing which shows a conventional product (1). It is sectional drawing which shows a conventional product (2).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,41 Floor mat 2 Surface fiber layer 3 Back surface soft layer 4 Sound-absorbing material layer 11 Surface fiber layer base fabric 12 Surface fiber layer raising 20 Columnar part 21 Columnar part shaft part 22 Columnar part tip part 25 Through hole 26 Inclined Surface 31 Floor fiber layer 32 Base fabric of floor fiber layer 33 Raised floor fiber layer 50 First columnar part 60 Second columnar part

Claims (14)

In a floor mat having a surface fiber layer and a back surface soft layer made of a soft material,
The back soft layer is
A plurality of through-holes that pass through the upper and lower surfaces of the back soft layer and are arranged in a predetermined pattern when the back soft layer is viewed from above or below;
A shaft portion extending downward from the lower surface and having the same cross section from the lower surface to a predetermined position near the tip is provided, and is arranged in a predetermined pattern when the back soft layer is viewed from above or below. A floor mat comprising a plurality of columnar portions.   2. The floor mat according to claim 1, wherein the back surface soft layer has an inclined surface that surrounds the lower surface openings of the plurality of through-holes and spreads in a mortar shape from the through-holes toward the radially outer side. .   The plurality of columnar portions include a first columnar portion having a predetermined length in the vertical direction and a second columnar portion having a shorter length than the first columnar portion, and the back surface soft layer is disposed above the first columnar portion. The floor mat according to claim 1 or 2, wherein the first columnar portion and the second columnar portion are arranged in a predetermined pattern when viewed from below.   The floor mat according to any one of claims 1 to 3, wherein a diameter of the columnar part is 2 to 6 mm, and a length of the columnar part is 2 to 6 mm.   The floor mat according to any one of claims 1 to 4, wherein a length of the shaft portion in the columnar portion is 1 to 3.5 mm.   The said columnar part is arrange | positioned at the grid | lattice form at intervals of 5-20 mm, when the said back surface soft layer is seen from the upper direction or the downward direction. Floor mats.   The floor mat according to any one of claims 1 to 6, wherein an opening ratio of the through holes is 2 to 20%.   The floor mat according to any one of claims 1 to 7, wherein the back soft layer has a thickness of 0.5 to 2 mm. The surface fiber layer includes a base fabric and napping raised from the base fabric, the basis weight of the surface fiber layer is 500 to 3000 g / m ² , and the height of napping in the surface fiber layer is 3 to ²⁰ mm. The floor mat according to claim 1, wherein the floor mat is provided.   The floor mat according to any one of claims 1 to 9, wherein a sound-absorbing material layer having air permeability is interposed between the surface fiber layer and the back soft layer. 11. The floor mat according to claim 10, wherein the basis weight of the sound absorbing material layer is 100 to 1000 g / m ² , and the thickness of the sound absorbing material layer is 1 to 10 mm. When the opening ratio of the through hole is β (%), the length of the shaft portion is α (mm), and the thickness of the back soft layer is γ (mm), the following relational expression is satisfied. The floor mat according to any one of claims 1 to 11, wherein the floor mat is provided.

  The floor fiber layer is arrange | positioned under the said back surface soft layer in the floor mat in any one of Claims 1-12, and the space layer is formed between the floor fiber layer upper surface and the said back surface soft layer lower surface. A floor structure characterized by that. The floor structure according to claim 13, wherein the floor fiber layer includes a base fabric and napping raised from the surface of the base fabric, and the length of the napping is 0.5 to 3 mm.

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