JP2010083369A - Floor mat and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat making joint parts between mats inconspicuous and excellent in joint fixing properties, and to provide a method for manufacturing the same. <P>SOLUTION: This floor mat comprises a carpet layer (C) including a pile (P), and a backing layer (K) for supporting the carpet layer. A floor mat end face is covered by a covering means (1) for the floor mat end face composed by a base part (11) brought into face contact with a peripheral edge part of a bottom face of the backing layer and extending along the floor mat periphery, a pile fixing part (13) fixing the root of the pile at the peripheral edge part of the floor mat in the direction of the backing layer and a joint part (12) jointing the base part and the pile fixing part in at least a part of the range of the entire circumference of the floor mat, and the root of the pile at the floor mat peripheral edge part is fixed in the direction of the backing layer. The covering means is made by material having a shape retaining property, and one partner (2a) of the joint means is fixed at the covering means. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a floor mat (especially an automobile floor mat) and a method for manufacturing the same.

In a car such as a one-box car, a floor mat is generally laid on the entire floor surface. In a one-box car or the like, a seat rail is installed to move the second row seats. Therefore, it comprises two or more floor mats that can be connected at the position of the seat rail so that the floor mat can be laid or removed.
When composed of two or more floor mats as described above, there is a problem in that mated portions are conspicuous, the design is poor, and the sense of unity with the passenger compartment is impaired.

  For example, Patent Document 1 discloses a floor mat connection structure for connecting floor mats laid on the floor adjacent to each other, and a male connector and a female mold disposed at a connection edge of each floor mat. A connector combination is disclosed. Patent Document 1 describes that when the surface of the floor mat is fluffy or the floor mat has long hairs, the connecting portion may be covered (paragraph [0016]). It is not intended to be covered.

  Although it is not a floor mat composed of two or more sheets, Patent Document 2 states that “a floor mat having a carpet layer provided with a pile and a backing layer that supports the carpet layer, and a peripheral portion of the floor mat. A floor mat "(Claim 1) characterized in that the pile base is fixed in the direction of the backing layer by means other than the primary base fabric or yarn constituting the carpet. It is also disclosed that taping with tape and suture, overlock processing, or heat fusion can be used as the root fixing means (paragraph [0020]). In this floor mat, the pile at the peripheral edge is tilted in the peripheral direction, and the dissimilar material at the peripheral edge of the floor mat can be hidden, so that a sense of unity with the passenger compartment can be obtained. Patent Document 2 also describes that “a hook-and-loop fastener and a hook may be attached so that floor mats can be connected” (paragraph [0023]).

  When the hook-and-loop fastener is mounted by sewing, the pile is pressed when the mounting location is close to the peripheral edge, so that the covering action by the pile is impaired.On the other hand, when it is far from the peripheral edge, the fixing portion is far from being fixed. It becomes insufficient. In addition, when the hook-and-loop fastener is attached with an adhesive, the bottom surface of the backing layer at the peripheral edge (that is, the bottom surface of the floor mat immediately below the pile fixing portion) is not smooth, and therefore it is usually adhered to a location far from the peripheral edge. However, in this case, a problem similar to that of the sewing attachment of the hook-and-loop fastener occurs. Further, when the hook is mounted, the same problem as that of the hook and loop fastener sewing occurs.

JP 2005-67227 A JP 2005-211108 A

  Therefore, an object of the present invention is to solve the above-mentioned disadvantages of the prior art, the mating portion between mats is not conspicuous, has excellent design, has a sense of unity with the passenger compartment, and has excellent connection and fixing properties. It is in providing the manufacturing method.

The subject is a floor mat (M) comprising a carpet layer (C) provided with a pile (P) and a backing layer (K) supporting the carpet layer according to the present invention,
A pile that can be in surface contact with the peripheral edge of the bottom surface of the backing layer and that can be fixed in the direction of the backing layer at the base portion (11) extending along the peripheral edge of the floor mat, and at the base of the pile at the peripheral edge of the floor mat. The floor mat end surface covering means (1) comprising the fixing portion (13) and the connecting portion (12) connecting the base portion and the pile fixing portion, the floor mat in at least a part of the entire circumference of the floor mat. The edge of the mat is covered and the pile root at the periphery of the floor mat is fixed in the direction of the backing layer;
The covering means is made of a material having shape retention;
One partner (2a) of the connecting means is fixed to the covering means;
This can be solved by a floor mat.

The present invention also provides a floor mat comprising a carpet layer provided with a pile and a backing layer that supports the carpet layer. A floor mat manufacturing method in which an end face of the floor mat is covered in at least a part of the area, and a pile root at the periphery of the floor mat is fixed in the direction of the backing layer,
With the floor mat end surface covering means disposed at a predetermined position of the end of the floor mat, the floor mat and its end surface covering means are placed on the floor layer side mold that can come into surface contact with the backing layer, and the pile eye direction is set to the floor. A step of placing between the pile side molds which can be aligned in the mat end direction,
The present invention relates to the above manufacturing method, comprising the step of fixing the floor mat end surface covering means to the end of the floor mat in a state where the eye direction of the pile is aligned in the direction of the end of the floor mat.

The floor mat of the present invention is not affected by the structure of the floor mat (for example, as described in Patent Document 1, limited to cases where the surface of the floor mat is fluffy or the floor mat has long hairs. Since the pile base at the periphery of the floor mat is forcibly fixed in the direction of the backing layer by the pile fixing part, it is evenly distributed to the periphery of the floor mat regardless of the direction of the eyes of the carpet. Since the pile falls and the peripheral edge of the floor mat is covered with the pile, the peripheral edge of the floor mat and the connecting portion are not conspicuous, the design is excellent, and a sense of unity with the vehicle interior is obtained.
Moreover, since the connection means is fixed to the covering means having shape-retaining properties, the floor mat of the present invention is excellent in connection and fixation between mats.

FIG. 1 is an enlarged partial cross-sectional view of the periphery of the floor mat, schematically showing the structure of a typical embodiment of the floor mat of the present invention.
A floor mat M shown in FIG. 1 includes a carpet layer C in which a pile P is fixed to a primary base fabric B, and a first backing layer K1 and a second backing layer K2 as backing layers K that support the carpet layer C. Yes.

  A covering member that covers the edge E of the floor mat M (that is, the end face of the backing layer K and the end face of the primary base fabric B) and fixes the pile Pe at the periphery of the floor mat in a predetermined direction. 1 is installed. The covering member 1 is made of a material capable of maintaining its own shape, and includes a base portion 11, a connecting portion 12, and a pile fixing portion 13. The base portion 11 is fixed in surface contact with the second backing layer K2, which is the lowermost layer of the backing layer, and the connecting portion 12 covers the end surface of the floor mat. The pile fixing portion 13 is fixed to the upper surface of the primary base fabric B at the peripheral portion by surface contact, and the base of the pile Pe at the peripheral portion is the backing layer K (the first backing layer K1 and the second backing layer K2). It is fixed in the direction.

  A hook-and-loop fastener 2a (for example, a hook-and-loop fastener having a hook) is fixed to the base portion 11 of the covering member 1 of the floor mat M as one partner of the connecting means. In the floor mat M shown in FIG. 1, for example, as shown in FIG. 2, another hook-and-loop fastener 2 b (for example, a hook-and-loop fastener having a loop) that is paired with the floor mat M is fixed to the base portion 11 of the covering member 1. It can be connected to another floor mat M ′ of the present invention by a hook-and-loop fastener. The surface fastener 2a can be fixed to the base portion 11 of the covering member 1 of the floor mat M by, for example, an adhesive, sewing, welding, or integral molding. On the other hand, the surface mat 2 ′ is fixed to the base portion 11 of the covering member 1 by causing a partial area of the floor mat M ′ to come into surface contact with the bottom surface of the base portion 11. For example, the hook-and-loop fastener 2b can be fixed to the base portion 11 by an adhesive, sewing, welding, or integral molding.

  In such a floor mat, since the base of the pile Pe at the peripheral edge E of the floor mat is fixed by the pile fixing portion 13, the pile Pe does not fall off at the peripheral edge E of the floor mat. Further, since the base of the pile Pe at the peripheral edge E of the floor mat is forcibly fixed in the direction of the backing layer K by the pile fixing portion 13, it is uniform toward the peripheral edge Ea side of the floor mat regardless of the direction of the eyes of the carpet. Since the pile Pe falls down and the peripheral edge E of the floor mat is covered with the pile Pe, the peripheral edge E and the connecting portion of the floor mat are not conspicuous, and the design is excellent and a sense of unity with the vehicle interior is obtained. .

  In FIG. 1, the “pile at the peripheral edge of the floor mat” is the pile Pe in the first row from the peripheral edge Ea of the floor mat M. The piles in the second and subsequent rows from the periphery E of the floor mat may be used as long as they can be concealed so as not to stand out. In addition, “root” means a position where the periphery of the floor mat and the connecting part can be concealed by fixing the pile, and it is limited because it depends on the length of the pile hair. In general, it is a range from the end of the pile on the primary base fabric surface side or the yarn surface side to about 3 mm in the pile protruding direction. Further, the “backing layer direction” is a direction in which the fixing force vector intersects the backing layer surface, and as shown in FIG. 1, the fixing force vector and the first backing layer K1 surface are orthogonal to each other. The pile Pe can be easily tilted in the direction of the peripheral edge Ea of the floor mat M, which is suitable for the fixing process.

When the covering member 1 having the shape shown in FIG. 1 is used, the dimensions can be appropriately determined depending on the dimensions of the carpet layer and the backing layer of the floor mat used at the same time. An example is shown below. In addition, the symbol (AF) shown in the parenthesis after each site | part means the symbol in FIG.
Thickness (A) of connecting part 12: 0.5 to 3 mm
Pile fixing portion 13 thickness (B): 0.5-3 mm
Distance (C) between bottom surface of base portion 11 and bottom surface of pile fixing portion 13: 3.5 to 7.5 mm
Distance (D) between top surface of base portion 11 and bottom surface of pile fixing portion 13: 3 to 7 mm
Pile fixing part 13 length (E): 1 to 8 mm
Pile P length (F): 13 mm or more

  The material of the covering member used in the floor mat of the present invention has a hardness of 30 so that the pile can be easily collapsed, has a certain degree of flexibility, is easily connected, and is not easily disconnected. It is preferable that it is -90 (Shore hardness A). Examples of such resins include polyamide, polyester, polypropylene, polyethylene, thermoplastic elastomer, thermosetting resin, natural or synthetic rubber, and various engineering plastics.

  The carpet used in the floor mat of the present invention is only required to have a pile, and the pile is fixed to the yarn even if it is fixed to the primary base fabric B as shown in FIG. There may be. More specifically, it can be composed of Unicom, Wilton carpet, Axisminster carpet, double face carpet, hook drag, tufted carpet, flock carpet, cord carpet, knitted carpet and the like.

  In addition, it is preferable to include atypical cross-section fibers as the fibers constituting the pile, because the pile is likely to be bulky, the pile is liable to collapse, and the floor mat and the connecting portion are easily covered. . The atypical cross-section fiber refers to a fiber having a non-circular cross-sectional shape, for example, an ellipse, an ellipse, an alphabet (for example, T shape, Y shape, X shape), a polygon (for example, a triangle, a quadrangle, etc.) ) And the like. In addition, a circular cross-section fiber or a modified cross-section fiber having a hollow portion in which no resin is present is also preferable because it has the same effect. Since the higher the content of such atypical cross-section fiber, the better the performance, it is preferable that 30 mass% or more of the pile is composed of the atypical cross-section fiber, and 70 mass% or more is the atypical cross-section fiber. More preferably, 100 mass% is comprised of atypical cross-section fibers.

In addition to the piles including the irregular cross-section fibers as described above, a pile that is easy to open (40 to 200 T / m), a pile that has a large basis weight (1000 g / m ² or more), and a low specific gravity of 0.9 to 1. A pile made of (0 g / cm ³ ) fiber (for example, polypropylene fiber) can be suitably used because it can easily be bulky, the pile can easily fall down, and the peripheral edge and the connecting portion of the floor mat can be easily covered.

  The floor mat of the present invention includes one or more backing layers that support the carpet layer, and this backing layer provides durability, sound insulation, sound absorption, anti-slip properties, water insulation, vibration control, and the like. At least one function is imparted to the floor mat. In FIG. 1, a first backing layer and a second backing layer are provided. Thus, the backing layer need not be a single layer, and may be provided with two or more layers.

Specifically, the material that can constitute this backing layer is (1) a thermoplastic resin sheet, (2) a thermoplastic elastomer sheet, (3) a thermosetting resin sheet, (4) a natural or synthetic rubber sheet, (5) An ultra-fine non-woven fabric containing ultra-fine fibers having a fiber diameter of 10 μm or less, which is generated by dividing a split fiber with a fluid flow such as a water stream, and (6) a fiber diameter of 10 μm generated by extracting and removing the resin component of the split fiber. (7) Ultrafine nonwoven fabric containing ultrafine fibers having a fiber diameter of 10 μm or less, (8) Bulky nonwoven fabric having a thickness (at a load of 10 g per 1 cm ² ) of 1 mm or more. (Needle punched nonwoven fabric, heat-sealed nonwoven fabric, melt blown nonwoven fabric having a fineness of 6.6 dtex or more), (9) foam, etc. Can be made.

  The connecting means that can be used in the floor mat of the present invention include, for example, a connecting means using fitting grooves shown in FIG. 4 and a connection based on meshing shown in FIG. 5 in addition to the hook-and-loop fastener shown in FIGS. Means can be mentioned.

  In the floor mats M and M ′ shown in FIG. 4, one floor mat M includes a hook support portion 31 a that extends horizontally from the upper end of the connecting portion 12 outward, a downward extension from the tip of the hook support portion, and The connecting means 3a includes the connecting portion 12 and the hook portion 32a that can form the fitting groove 39a together with the hook supporting portion 31a. The other floor mat M ′ includes a hook support portion 31b extending horizontally outward from the lower end of the connecting portion 12, and extending upward from the tip of the hook support portion, and the connecting portion 12 and the hook support portion 31b. The connecting means 3b is formed of a hook portion 32b that can form a fitting groove 39b together. By fitting the hook portion 32a of the floor mat M to the fitting groove 39b of the floor mat M ′ and the hook portion 32b of the floor mat M ′ to the fitting groove 39a of the floor mat M, respectively, The floor mat M and the floor mat M ′ can be connected. When the hooks 32a and 32b have a semicircular cross section as shown in FIG. 4, they can be easily fitted.

  In the floor mats M and M ′ shown in FIG. 5, one floor mat M includes a support portion 41 a that extends horizontally from the upper end of the connecting portion 12 outward, and a meshing protrusion that extends downward from the tip of the support portion. The connecting means 4a which consists of the part 42a is provided. The other floor mat M ′ includes a connecting means 4b including a support portion 41b extending horizontally outward from the lower end of the connecting portion 12 and an engaging protrusion 42b extending upward from the tip of the support portion. ing. By engaging the engaging protrusion 42a of the floor mat M and the engaging protrusion 42b of the floor mat M ', the floor mat M and the floor mat M' can be connected.

  In the floor mat after connection shown in FIG. 4 or FIG. 5, the root of the pile Pe at the peripheral edge E of the floor mat is forcibly fixed in the direction of the backing layer K by the pile fixing portion 13, so Regardless of the direction of the eyes, the pile Pe falls uniformly toward the peripheral edge Ea of the floor mat, and the connecting portion between the floor mats is covered and covered by the pile Pe, so the connecting portion of the floor mat is not conspicuous and has excellent design. A sense of unity with the passenger compartment is obtained.

In addition, when using the hook-and-loop fastener shown in FIG. 2 or the meshing connecting means shown in FIG. 5 as the connecting means, the connecting means itself is not easily displaced in the longitudinal direction, so, for example, even when there is no seat rail, It is excellent in connecting and fixing mats, and is effective, for example, in connecting the rear and rear center of a sedan-type automobile.
When the connecting means using the fitting groove shown in FIG. 4 is used as the connecting means, a lid is installed at the end in the longitudinal direction of the connecting means, or the end in the longitudinal direction is deformed by heat treatment, etc. By reducing the size of the groove, it is possible to make it difficult to shift in the longitudinal direction of the connecting means. In this case as well, excellent mating and fixing properties between the mats can be exhibited as described above.

  The floor mat of the present invention can be manufactured, for example, by the manufacturing method of the present invention. In the production method of the present invention, a backing layer side mold that can come into surface contact with the backing layer of the floor mat and a pile side mold that can come into contact with at least the tip of the pile layer are used, and the floor mat end surface covering means is used as the floor mat. The floor mat and its end surface covering means are disposed between both molds in a state where the floor mat is disposed at a predetermined position on the end.

For example, in the embodiment shown in FIG. 6 which is an example of the manufacturing method of the present invention, a concave mold 81 in which a floor mat can be disposed in the inner space is used as the backing layer side mold, and the pile side mold is used. An inclined flat plate mold 91 is used. As shown in FIG. 6B, the inclined flat plate mold 91 has a thickness that continuously increases along the direction from the periphery to the center of the floor mat, forming an inclination.
First, as shown in FIG. 6 (a), the floor mat M and the covering member 1 are formed on the backing layer side mold in a state where the covering member 1 as the floor mat end face covering means is disposed at the end of the floor mat M. In the inner space of the concave mold 81, the bottom surface of the floor mat M and the inner wall of the inner space are arranged in surface contact. In general, carpets have an eye direction (pile inclination), and in the manufacturing method of the present invention, it is an object of the present invention to provide a floor mat in which the eye direction of the pile at the peripheral part is aligned with the peripheral direction of the floor mat. Yes. In FIG. 6 (a), the pile eyes are all inclined toward the center of the floor mat, but the manufacturing method of the present invention can be applied to a floor mat of any eye direction.
When the floor mat and the covering member are fixed with an adhesive [for example, fused with a hot-melt resin (for example, polyamide)], the adhesive is interposed between the floor mat M and the covering member 1. It can be placed between both molds. When a hot melt resin is used as the adhesive, for example, an ultrasonic wave generating means (not shown) can be arranged outside the concave mold 81 and fusion can be performed by ultrasonic waves.

Next, as shown in FIG. 6B, an inclined flat plate mold 91 that is a pile side mold is placed at a predetermined position so as to be in contact with at least the tip of the pile layer. At this time, the surface of the inclined flat plate mold 91 that does not come into contact with the pile P (hereinafter referred to as a reference surface 91a; the opposite surface is referred to as a pile contact surface 91b) is parallel to the bottom surface of the floor mat. By maintaining, the pile contact surface 91b is inclined. The pile tip that is in contact with the pile contact surface 91b is inclined in the peripheral direction of the floor mat according to the inclination of the pile, so that the eye direction of the pile can be aligned with the end direction of the floor mat.
In the embodiment shown in FIG. 6, not only the inclined flat plate mold 91 having a single inclination shown in FIG. 6 (b) but also two or more inclinations as shown in FIG. 6 (c) can be used. It is also possible to use an inclined flat plate mold 92 having the same.

In this state, by performing a process of fixing the covering member 1 to the floor mat M (for example, fusion by ultrasonic waves), the floor mat in which the pile root at the periphery of the floor mat is fixed in the direction of the backing layer Can be manufactured.
The floor mat (for example, see FIG. 1) of this invention can be manufactured by fixing the surface fastener 2a to the obtained floor mat with an adhesive, for example. Alternatively, instead of the covering member 1 used in FIG. 6, for example, a floor mat (for example, see FIG. 1) of the present invention is used by using a covering member in which a surface fastener is fixed in advance by adhesive, sewing, or integral molding. ) Can be manufactured. Furthermore, instead of the covering member 1 used in FIG. 6, the floor mat according to the present invention (see, for example, FIG. 4 or FIG. 5) is obtained by using a floor mat end face covering means and a connecting means that are integrally molded in advance. Can be manufactured.

In the embodiment shown in FIG. 7 which is another example of the manufacturing method of the present invention, a concave mold 82 in which a floor mat can be arranged in the internal space is used as the backing layer side mold, and the pile side mold is used. A movable flat mold 93 is used.
First, as shown in FIG. 7A, in a state where the covering member 1 is disposed at the end of the floor mat M, the floor mat M and the covering member 1 are placed in the interior space of the concave mold 82. The bottom surface of the backing layer and the inner wall of the inner space are in surface contact. In FIG. 7 (a), the pile eye directions are all inclined toward the center of the floor mat, but the manufacturing method of the present invention can be applied to a floor mat of any eye direction. Subsequently, the flat plate mold 93 is placed in contact with at least the tip of the pile layer.
Next, when the flat plate mold 93 is moved in the peripheral direction of the floor mat (that is, the direction indicated by the arrow A), as shown in FIG. 7B, the pile P that has been in contact with the pile contact surface 93b. As the flat plate mold 93 moves, the front end of the plate can be inclined in the peripheral direction of the floor mat so that the eye direction of the pile can be aligned with the end direction of the floor mat.
In this state, by performing a process of fixing the covering member 1 to the floor mat M (for example, fusion by ultrasonic waves), the floor mat in which the pile root at the periphery of the floor mat is fixed in the direction of the backing layer Can be manufactured.

  The floor mat of the present invention can be applied to, for example, an automobile floor mat.

It is an expanded partial sectional view of the floor mat peripheral part which shows typically the structure of the one aspect | mode of the floor mat of this invention which uses a hook_and_loop | surface fastener as a connection means. It is a typical expanded partial sectional view of a floor mat peripheral part of one mode of a floor mat of the present invention shown in Drawing 1 and another mode of a floor mat of the present invention which can be connected by a hook-and-loop fastener. It is an expanded partial sectional view of a floor mat peripheral part which shows typically one mode of a floor mat of the present invention shown in Drawing 1 in the state where a connection means was removed. It is an expanded partial sectional view of a floor mat peripheral part showing typically another one mode (a set of 2 sheets) of a floor mat of the present invention which has a connection means by a fitting slot. It is an expanded partial sectional view of a floor mat peripheral part showing typically another one mode (a set of 2 sheets) of a floor mat of the present invention which has connection means based on meshing. Each step [FIG. 6 (a), FIG. 6 (b)] in one embodiment of the floor mat manufacturing method of the present invention, and the structure of an inclined flat plate mold (FIG. 6 (c)) usable therein are schematically shown. It is explanatory drawing shown in. It is explanatory drawing which shows typically each process [FIG.7 (a), FIG.7 (b)] in another one aspect | mode of the floor mat manufacturing method of this invention.

Explanation of symbols

M, M '... floor mat;
C ... carpet layer; P ... pile; K ... backing layer;
1 ... Floor mat end face covering means;
11 ... Base part; 12 ... Connection part; 13 ... Pile fixing part;
2a, 2b, 3a, 3b, 4a, 4b ... connecting means;
81, 82 ... backing layer side mold; 91, 92, 93 ... pile side mold.

Claims (2)

A floor mat having a carpet layer with a pile and a backing layer that supports the carpet layer,
A base portion extending along the periphery of the floor mat, and a pile fixing portion capable of fixing the pile root at the periphery of the floor mat in the direction of the backing layer; In addition, the floor mat end surface covering means covering at least a part of the entire circumference of the floor mat is covered with a floor mat end surface covering means comprising the base portion and the connecting portion connecting the pile fixing portions, and the periphery of the floor mat The pile root in the section is fixed in the direction of the backing layer;
The covering means is made of a material having shape retention;
One partner of the connecting means is fixed to the covering means;
A floor mat characterized by that. A floor mat comprising a carpet layer provided with a pile and a backing layer for supporting the carpet layer, wherein at least a part of the entire circumference of the floor mat is formed by the covering means on the end surface of the floor mat according to claim 1. In the manufacturing method of the floor mat, the end surface of the floor mat is covered, and the root of the pile at the periphery of the floor mat is fixed in the direction of the backing layer,
With the floor mat end surface covering means disposed at a predetermined position of the end of the floor mat, the floor mat and its end surface covering means are placed on the floor layer side mold that can come into surface contact with the backing layer, and the pile eye direction is set to the floor. A step of placing between the pile side molds which can be aligned in the mat end direction,
The manufacturing method according to claim 1, further comprising a step of fixing the floor mat end surface covering means to the end of the floor mat in a state in which the eye direction of the pile is aligned with the end of the floor mat.

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