JP2987097B2 - Carpet mat for laying and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet mat for laying, which is laid on the floor of an indoor or entrance of an automobile, a house, various facilities, etc., to prevent dirt such as soil, mud, dust and the like from scattering. It relates to a manufacturing method.

[0002]

2. Description of the Related Art A carpet mat for laying is obtained by backing the back of a carpet made of woven or knitted fibers with rubber latex or by cutting a raw material lined with a rubber or plastic sheet into a desired shape and size. Can be
However, if this cut material is used as it is, there is a problem that the cut surface is exposed and the appearance is poor and the product is easily frayed. For this reason, conventionally, a trimming molding made of cloth, rubber, soft plastic, or the like has been sewn to a cut surface to cover it. Further, the cut surface is also covered by a process such as overlock sewing. Specifically, the following processing is known.

(1) A tape made of a soft plastic film, a tape made of a flexible fiber, a tape obtained by laminating a thin cloth on the back of a soft plastic film, or the like, using a tape guide, the periphery of a carpet mat. Is wrapped around the carpet mat, which is sewn to the periphery of the carpet mat with a sewing machine, and the carpet mat is trimmed.

(2) A wool-like thick yarn is used as an upper yarn,
Overlock sewing machine (Hover etching sewing machine) is used as the lower thread, and the peripheral portion of the carpet mat is overlock-stitched, trimmed, and trimmed.

[0005] (3) A long, round U-shaped edging mall made of soft plastic is coated on the periphery of the carpet mat through a mall guide, and the carpet mat is sewn with a sewing machine to be shaped.

(4) The cut surface of the peripheral portion of the carpet mat made of synthetic fiber is melted and shaped using a hot press, a high-frequency welder or the like.

(5) First, vulcanization molding, compression molding, and the like are performed using a molding die capable of molding a peripheral portion having a required shape made of rubber or soft plastic and a carpet backing portion inside the peripheral portion. To form a pedestal portion, and a carpet of a required shape is laminated on the carpet lining portion of the pedestal portion by a bonding method or the like, thereby backing the carpet and shaping the peripheral cutting section.

(6) A lower molding die having a peripheral molding portion having a required shape, a preparation portion for a carpet having a required shape inside thereof, and a rubber molding portion for lining on the bottom surface thereof, and a pair of upper metal molding members. First, an unvulcanized rubber sheet is charged into the lower molding die using a mold, and then a carpet of a required shape is charged thereon, and the upper and lower molding die are molded. By pressing, heating and vulcanizing, the peripheral rubber and the backing rubber are integrally formed on the carpet.

(7) The peripheral portion of the carpet mat is covered with a U-shaped soft plastic edging molding containing a U-shaped aluminum core material. By attaching the opening of the molding by crimping, the edging molding is fixed to the periphery of the carpet mat.

(8) As shown in FIG. 6, it has a pair of long, opposing horizontal strips made of a soft plastic and a strip-shaped connecting part for connecting the pair of horizontal strips.
The fringing molding 12 having the band-shaped protrusions 14 in which the band-shaped connecting portions extend upward is coated on the peripheral portion of the carpet mat through a molding guide, and is sewn with a sewing machine to be shaped (Japanese Patent Application No. Hei. -39052).

[0011]

Among the carpet mats manufactured by the above-mentioned conventional methods, (1), (2) and (3)
The sewing machine sewing shown in (8) and (8)
As compared with those of (5) and (6), the appearance is better in order not to impair the raising. These sewing machines are used most frequently because they can efficiently produce carpet mats corresponding to various shapes without requiring a molding die or a large molding facility.

However, in the above (1), (2) and (3), the edging portion is located at a position lower than the raised surface of the carpet. For this reason, there is a problem that, when actually laid in a room, earth and sand, dust, and the like are spilled from a peripheral edge portion, and the room is easily stained. In particular, when moving the mat for cleaning, earth and sand, dust, dirt, and the like easily fall off the mat. In addition, the carpet mat for laying that has been treated as described in (7) must be surrounded and covered with the periphery of the soft carpet mat by using an edge molding that incorporates an aluminum core material that does not expand or shrink. Is impossible.

In the carpet mat for laying shown in (8), a band-like projection 14 higher than the raised hair is provided on the outermost peripheral edge of the molding 12 to prevent spilling of earth and sand. However, after sewing, such protrusions, especially at the peripheral bend of the carpet mat, may be A, as shown in FIG.
B In many cases, it was inclined in either direction. Such a band-shaped projection cannot exhibit a sufficient function to prevent spilling of earth and sand, etc., and a carpet mat for laying down using the band-shaped projection still has a problem that the room is easily soiled. Was.

The present invention is to prevent the protrusion provided on the trimming molding from being inclined during or after sewing, so that the effect of preventing spilling of soil and the like can be sufficiently exhibited in the carpet mat for laying. With the goal.

[0015]

SUMMARY OF THE INVENTION The present invention includes a pair of opposed horizontal strips made of a soft material, and a strip connecting part connecting the pair of horizontal strips, and a pair of horizontal strips above the pair of horizontal strips. In the carpet mat for laying, in which the peripheral cut section of the carpet mat cut into a predetermined shape is covered by the edging mall in which a ridge portion higher than the raised brush of the carpet is provided on the upper surface of the horizontal band-shaped portion, the edging mall Is located at a position sandwiching the center line of the upper surface of the upper horizontal strip, the pier is hollow, and when the pier is cut in a cross section, it has a mountain shape. The edging mall is fixed to a peripheral cutting section of the carpet mat at positions along both sides of the jetty section, and the jetty section is formed around the entire peripheral section of the carpet mat. Over and it provided continuously, but according to the carpet mat 置敷.

According to the present invention, in order to obtain such a carpet mat for laying, the peripheral cutting section of the carpet mat is continuously covered by using the trimming molding, and at a position along both sides of the jetty. This is a method of manufacturing a carpet mat for laying, in which an edging mall is fixed to a peripheral cutting section of the carpet mat.

Further, according to the present invention, in order to obtain such a carpet mat for laying, a molding guide for continuously covering the trimming molding on a peripheral cutting section of the carpet mat is provided in front of a sewing needle of a two-needle feeding type sewing machine. This is a method of manufacturing a carpet mat for laying, wherein the carpet mat is fixed at a position, and the trimming molding is fixed to a peripheral cutting section of the carpet mat through the molding guide.

Further, according to the present invention, in order to obtain such a carpet mat for laying, a molding guide has a central guide space portion for guiding a peripheral cutting section of the carpet mat into the molding mall, and an upper portion of the central guide space portion. An upper guide space portion for guiding the upper horizontal band portion and the jetty portion of the edging mall, and a lower guide space portion for guiding the lower horizontal band portion of the edging mall below the central guide space portion. Including, the band-shaped connecting portion of the edging mall is guided by the inner wall surface on the back side of the central guide space portion, and the peripheral cutting section of the carpet mat is continuously covered with the edging mall,
This is a method for producing a carpet mat for laying.

The present inventor has studied the cause of the inability of the conventional belt-shaped projection to exhibit a sufficient function for preventing spilling of earth and sand.

This study was conducted by using a conventional edging molding to cover the periphery of the carpet mat by sewing. The cause was found in the following points.

When the edging molding is curved along the curved portion of the peripheral portion of the carpet mat, a portion inside the center line of the horizontal band portion of the edging molding is largely compressed in the length direction, and an outer portion is compressed. It was found to be greatly stretched. In addition, the force applied to the upper horizontal band is greater toward the left and right ends in the vertical section of the upper horizontal band,
Smaller near the center line. Therefore, a strong force is applied to the conventional band-shaped projection 14 located at the outer end of the upper horizontal band as shown in FIG. 6, and this band-shaped projection 14 is deformed. As a result, the conventional band-shaped projection 14
Is inclined inward (A direction) at the peripheral curved portion.

As described above, the inventor of the present invention has the disadvantage that the conventional molding for preventing spilling of soil and the like has a structural defect, and this molding is curved along the peripheral curved portion of the carpet mat. It was found that the distortion occurred in the case. The distortion applied to the horizontal strip deforms the protrusion provided on the upper surface. The deformation of the projection has an adverse effect on the finish of the carpet mat for laying. In particular, when a jetty portion higher than the raised portion is provided to prevent spillage of soil and the like, the function and appearance of the laid carpet mat in which the jetty portion is deformed are impaired, and its commercial value is reduced. From such a viewpoint, the jetty used in the present invention is:
In particular, the installation position is important, and it is important to maintain strength so that the height does not fluctuate due to deformation.

In the present invention, the jetty portion is provided in the trimming molding made of a soft material. The portion on the center line of the upper horizontal band is a position where there is little dimensional change in the length direction,
At a position sandwiching this center line, a jetty portion is arranged at least on the peripheral curved portion of the carpet mat. In the trimming molding according to the present invention employing such a structure, a jetty portion is provided substantially at the center of the upper surface of the upper horizontal strip portion. Thereby, it can prevent that a jetty part falls inward in a curved part. In addition, expansion and contraction of the jetty portion is reduced, and the edging mall can be easily and smoothly covered along the peripheral portion of the carpet mat. In the carpet mat for laying having such a structure, a pier portion higher than the raised surface of the carpet is sufficiently secured, so that it is possible to effectively prevent earth and sand, dust and the like from spilling out of the mat.

In the present invention, a hollow portion is provided at the center of the jetty. This gives flexibility to the jetty. By using the edging molding having such a jetty portion, the curved portion of the carpet mat is easily covered along the peripheral edge portion. In addition, such a jetty can withstand some deformation, positioning is easy at the time of sewing, and variation in the shape after sewing is reduced. Furthermore, in the edging mall having such a jetty portion, the thickness of each portion is substantially uniform. Therefore, when the edging molding is manufactured by extrusion, since the extrusion speed of each part is equalized, distortion is hardly generated in the extrusion shape.

Further, in a preferred embodiment of the present invention, a sewing machine is used as a sewing device for a carpet mat for laying. Sewing with a sewing machine or the like uses a trimming molding to fix the carpet mat while continuously covering the peripheral cutting section.
Therefore, a carpet mat for laying can be easily manufactured without impairing productivity.

It is preferable to use a sewing machine in which a molding guide is fixed at a position before the sewing needle on the sewing machine table, in particular, a two-needle needle feed type sewing machine. With the sewing machine, the upper horizontal band, the periphery of the carpet mat, and the lower horizontal band are simultaneously sewn at positions along both sides of the jetty. The pier section sewn in this manner sinks and is fixed during the raising of the carpet mat evenly on the left and right sides, and the pier section does not tilt. The sewn carpet mat after sewing is excellent in appearance, has a high spill prevention effect, and is durable.

The molding guide used for sewing according to the present invention has a central guide space for guiding the peripheral cut section of the carpet mat into the trimming molding. The central guide space is open in one direction when the molding guide is cut along the cross section. When the molding guide is cut along the longitudinal section, both ends of the center guide space are open. In addition, this mall guide includes an upper horizontal band portion and a jetty portion of the trimming mall,
An upper guide space portion and a lower guide space portion for guiding the lower horizontal band portion of the edging mall are provided above and below the central guide space portion, respectively. The upper guide space and the lower guide space are open at both ends when the molding guide is cut along a longitudinal section. These guide portions are fixed to the guide support plate, guide the band-shaped connecting portion of the edging mall on the inner wall surface on the back side of the central guide space portion, and continuously cut the peripheral cutting section of the carpet mat with the edging mall. Can be coated.

[0028]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in more detail with reference to the drawings. FIG. 1 is a plan view of a carpet mat for laying of an example of the present invention as viewed from above, and FIG. 2 is a cross-sectional view of a part of FIG. 1 (a cross-section showing a state where a trimming molding is attached to a peripheral portion of the carpet mat). FIG. 3 is a sectional view of the molding for trimming, FIG. 4 is a front view of the molding guide, and FIG. 5 is a front view showing a state where the molding for molding is passed through the molding guide.

The raw material 2 of the carpet used in the present invention is:
Needle punched carpets, tufted carpets made of natural fibers, synthetic fibers and the like can be produced by various other production methods. In order to manufacture the carpet mat 6 according to the present invention, first, the raw material 2 of the carpet and the sheet-like backing material 5 made of rubber (natural rubber, synthetic rubber) or thermoplastic elastomer (for example, soft vinyl chloride) are used. And affix with an adhesive. Further, in such a method, it is also possible to simultaneously bond the raw material 2 of the carpet and the sheet-like backing material 5 at the time of vulcanizing the rubber, or to heat-bond a thermoplastic elastomer sheet. Thereafter, the laminate is cut into a predetermined shape. In addition, it is preferable to provide a pattern serving as a non-slip and a non-slip projection 7 on the back surface of the backing material 5.

The trimming molding 3 used in the present invention is shown in a sectional view in FIG. The edging molding 3 has a pair of horizontal belts facing each other (an upper horizontal belt 3a and a lower horizontal belt 3b) and a belt-like connecting portion 3c connecting the pair of horizontal belts. In addition, in this edging mall 3,
A jetty 3d having a height higher than the raised surface 2a of the carpet is provided along a substantially central portion on the surface of the upper horizontal strip 3a. The jetty portion 3d has an effect of preventing earth and sand, dust, and the like from spilling out of the mat in the laid carpet mat 1 after molding.

The jetty 3d must be provided at least on the peripheral curved portion 4 of the carpet mat shown in FIG.
In addition, it is preferable to be provided on the entire periphery of the carpet mat. The reason is that, in the peripheral curved portion 4, particularly, the expansion and contraction of the edging molding 3 is large, and the ridge portion 3 d is distorted. In addition, the shape of the jetty portion is preferably a mountain shape that can withstand some deformation, and the top portion may be flat.

A soft material such as a thermoplastic elastomer, which easily expands and contracts, is used for the material of the molding 3 so as to easily follow the curve of the peripheral portion of the carpet mat 6. As the edging molding 3, a material obtained by extruding this material into a long shape in the above-described form using an extruder is used.

The trimming molding 3 is attached to the carpet mat 6
When it is curved and covered along the curved portion of the peripheral portion of the belt, the longitudinal direction of the inner side of the band is largely compressed and the outer side is greatly extended, with the center line 10 of the horizontal band being the base line. . That is, the center line 10 is a position where the dimensional change is small in the length direction. In the present invention, the ridge 3d is prevented from falling inward at the peripheral curved portion 4 by providing the ridge 3d substantially at the center of the upper horizontal strip 3a with the center line 10 interposed therebetween. In addition, since the jetty portion 3d provided at such a position has less expansion and contraction, the edging mall 3 can be easily and easily covered along the peripheral curved portion 4 of the carpet mat 6.

Also, by providing a jetty hollow portion 3e as shown in FIG. 3 at the center of the jetty portion, the jetty portion 3d is easily curved along the peripheral curved portion 4 of the carpet mat 6. Each part of the edging molding 3 has a substantially uniform thickness due to the jetty hollow portion 3e. Therefore, when extruding the molding 3 for edging, the extrusion speed of the molding 3 for edging can be made uniform as a whole, and distortion of the extruded shape is less likely to occur.

As the sewing apparatus used in the present invention, a sewing machine in which the molding guide 11 shown in FIG. 4 is fixed at a position of the mounting hole 11e in front of a sewing needle on a sewing machine stand is used. In particular, when a two-needle needle feed sewing machine is used, the upper horizontal band-like portion 3a is formed at positions 8 and 9 along both sides of the jetty 3d.
, The peripheral portion of the carpet mat 6 and the lower horizontal band 3
b is sewn at the same time. In the carpet mat for laying manufactured in this way, the jetty portion 3d is settled in the raised carpet 2a of the carpet mat 6 on the left and right sides to be fixed. As a result, the jetty portion 3d is sewn without being inclined, and the obtained carpet mat for laying has an excellent appearance, has a high spill-prevention effect, and is durable.

The molding guide 11 used for sewing according to the present invention.
Are provided with various guide portions as shown in FIG. 4 for guiding a carpet mat and the like, and are fixed to a guide support plate 11d. These guides are on carpet mat 6
Central guide space 11b for fitting and guiding the peripheral portion of
An upper guide space portion 11a for guiding the upper horizontal band portion 3a and the ridge 3d of the edging mall 3 above the central guide space portion 11b, and a lower horizontal band portion of the edging mall below the central guide space portion 11b. 3b is a lower guide space 11c that guides 3b. The guide support plate 11d is provided with a hole 11e for attachment to a sewing machine stand.

Carpet mat 6 cut into a predetermined shape
And a trimming molding 3 made of a soft material are prepared.
The molding guide 11 was attached to the front position of the needle-feeding sewing machine with its attachment hole 11e, and these were sewn using a fixed sewing machine sewing device.

First, as shown in FIG.
1 corresponding to the respective guide space portions (11a, 11b, 11c), the corresponding portions (3a, 3d, 3c, 3c) of the molding 3 for edging.
Insert the end of b). Next, a predetermined position of the peripheral portion of the carpet mat 6 was fitted into the central guide space 11b from the side opening of the molding guide 11 and positioned below the sewing needle.

Next, the sewing machine is started, and the carpet mat 6 and the trimming molding 3 covering the periphery thereof are sequentially sent to the sewing needle, and simultaneously sewn using the inner sewing thread 8 and the outer sewing thread 9. . The sewing machine was temporarily stopped when the leading sewing position reached just before the mall guide 11 after being turned about once, and the subsequent trimming molding 3 was cut with scissors in accordance with the leading trimming molding 3. afterwards,
The carpet mat 6 and the trimming molding 3 were removed from the molding guide 11, the remaining sewing was sewn by hand, the seam was fastened, and the sewing thread was cut off.

[0040]

According to the present invention, the jetty portion higher than the raised portion of the carpet mat is disposed at a position sandwiching the center line of the upper horizontal band portion of the trimming molding. The laying carpet mat to which the edging molding having such a structure is fixed has a small expansion and contraction of the jetty even at the peripheral curved portion of the carpet mat, and the jetty does not fall down inside. Therefore, it is possible to remarkably remedy the drawbacks of the conventional product in that earth and sand, dust, dirt, and the like are easily spilled into the room from the mat surface during the erection in the room or when taking the device out for cleaning. Also,
The edging mall provided with the jetty according to the present invention can be easily and smoothly covered along the periphery of the carpet mat. Furthermore, the edging molding according to the present invention, in which the jetty portion is hollow, can withstand some deformation, facilitates positioning at the time of sewing, and reduces variation in the shape after sewing.

Further, the carpet mat for laying according to the present invention has advantages such as easy adaptation to edging malls of various shapes, excellent cost and workability, and less damage to the raised surface of the carpet. The sewing machine can be efficiently manufactured by using a conventional sewing method such as a two-needle needle feed sewing machine. Such a carpet mat for laying of the present invention can make the appearance more luxurious, does not impair the advantages of the conventional edging carpet mat, has a high spill prevention effect, and is durable.

[Brief description of the drawings]

FIG. 1 is a plan view showing an entire carpet mat for laying according to the present invention.

FIG. 2 is a cross-sectional view showing a broken surface of a part of FIG.

FIG. 3 is a cross-sectional view of a molding for edging having a hollow jetty according to the present invention.

FIG. 4 is a front view of a molding guide according to the present invention.

FIG. 5 is a partial cross-sectional front view showing a state in which an edge molding is passed through a molding guide according to the present invention.

FIG. 6 is a cross-sectional view showing a broken surface of a part of a conventional carpet mat for laying.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Carpet mat for laying 2 Carpet 2a Carpet raising 2b Carpet base cloth 3 Trimming molding 3a Upper horizontal band part 3b Lower horizontal band part 3c Band connection part 3d Projection embankment part 3e Projection hollow part 4 Peripheral curved part 5 Backing material 6 Carpet mat 7 Non-slip protrusion 8 Inner sewing thread 9 Outer sewing thread 10 Center line of upper horizontal band 11 Mall guide 11a Upper guide space 11b Center guide space 11c Lower guide space 11d Mall guide support plate 11e Attachment to sewing machine stand Hole 12 conventional molding for edging with strip projections 14 strip projections

Claims (4)

(57) [Claims] 1. A carpet comprising: a pair of opposed horizontal strips made of a soft material; and a band-like connecting part connecting the pair of horizontal strips, and a carpet on an upper horizontal strip of the pair of horizontal strips. In the carpet mat for laying, in which the peripheral cutting section of the carpet mat cut into a predetermined shape is covered by the edging mall provided with a ridge portion higher than the raised ridge, the ridge portion of the edging mall is the upper horizontal band shape. It is arranged at a position sandwiching the center line of the upper surface of the portion, the jetty portion is hollow, the jetty portion has a shape of a mountain when cut in a cross section, the edging mall is The carpet mat is fixed to the peripheral section of the carpet mat at positions along both sides of the jetty section, and the jetty section is provided continuously over the entire periphery of the peripheral section of the carpet mat. And wherein the are, carpet mat for 置敷. 2. A peripheral cutting of the carpet mat at positions along both sides of the jetty while continuously covering a peripheral cutting section of the carpet mat using the trimming molding. The method according to claim 1, wherein the mat is fixed to a surface. 3. A trim guide for continuously covering the trimming molding on a peripheral cutting section of the carpet mat is mounted at a position before a sewing needle of a two-needle feed sewing machine, and the trimming molding is passed through the molding guide. The method for producing a carpet mat for laying according to claim 2, wherein the molding is fixed to a peripheral cutting section of the carpet mat. 4. A center guide space for guiding the peripheral cutting section of the carpet mat into the edging mall, and the upper horizontal band of the edging mall above the central guide space. And an upper guide space portion for guiding the jetty portion, and a lower guide space portion for guiding a lower horizontal band-shaped portion of the edging mall below the central guide space portion. The belt-shaped connecting portion of the mall is guided by an inner wall surface on the back side of the central guide space portion, and a peripheral cutting section of the carpet mat is continuously covered with the trimming mall. Manufacturing method of carpet mat for laying.