JP4366460B2 - Floor mat and method for manufacturing the same - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a mat base, an edge portion that is integrated with the mat base at a predetermined portion of the peripheral edge portion of the mat base, has an arbitrary cross-sectional shape, and is formed to rise. The mat base And a novel method of manufacturing the floor mat comprising a carpet bonded to the edge surface. The floor mat of the present invention does not cause inconveniences such as edge curling or entanglement due to its unique and superior structure and physical properties, and has good followability to the floor surface shape, so that dust and dirt can be retained in the mat. In addition, it has the advantage of not cluttering, so it is used on the floor of buildings and transport vehicles.
[0002]
[Description of Related Art]
Various forms of mats are used on floors of buildings such as ordinary households, offices, hotels, stores, etc., floors of transportation vehicles such as automobiles, ships, airplanes, and railway vehicles. In particular, floor mats are used as water mats, entrance mats, hallway mats (runners), business mats (dust control mats), and automobile option mats for buildings.
[0003]
Roughly classifying such mats in terms of structure, so-called rubber mats, and carpets with piles such as woven carpets, in which rubber or a mixture of rubber and thermoplastic synthetic resin is molded into a predetermined shape by press molding or the like Or carpets without piles, such as felted needle punched carpets, and mat or mat bases, edges and mat bases made of rubber or a thermoplastic synthetic resin or a mixture of rubber and thermoplastic synthetic resin Or it is classified into the floor mat etc. which adhered the said various carpets on the mat base. The present invention is applied to a floor mat.
[0004]
In addition to decorativeness, the main purpose of use of the floor mat described above is to prevent floor dirt and improve the effects of soundproofing, vibration isolation, heat insulation, walking comfort, safety, and the like. In order to further enhance these effects, the carpet texture laminated on the mat base is preferably a carpet having piles such as cut, loop, cut & loop, etc., rather than a flat type without piles. With the recent trend toward luxury goods, carpets laminated on the mat base have piles and have a high density.
[0005]
A mat base made of rubber or a mixture of rubber and thermoplastic synthetic resin, and a floor mat of a flooring type in which various carpets are laminated on the mat base not only improve the above-mentioned effects, but also the mat base and the carpet move. It is essential that it is fixed so that it does not, that it follows the floor structure completely, and that the edge does not warp. If the floor mat does not satisfy these requirements, not only the floor contamination prevention, soundproofing, vibration isolation, heat insulation effect, etc. are fully exhibited, but also walking is dangerous.
[0006]
The mat base, which covers most of the floor mat, is usually made of rubber or thermoplastic synthetic resin or a mixture thereof and is different in material from the carpet. Therefore, it is not easy to join materials having various physical properties such as dimensional shrinkage so as not to be deformed with time. Also, floor mats that have uneven parts, such as building entrances or automobile floors, where people come and go, and are laid down in narrow spaces, can be stepped on and separated from the floor surface during use. Or, there is a disadvantage that it is involved, or that it moves from the place where it was first installed by sliding with the floor surface.
[0007]
Conventionally, various proposals have been made to eliminate these drawbacks. Typical examples of them are a method of sewing a border tape on the edge, a method of using a fastener with a floor surface such as a hook, a snap, and a fastener, a predetermined part of the mat base with a protruding shape and a floor surface. These are a method of reducing sliding friction by changing the contact to point contact instead of surface contact, or a method of fixing with an adhesive. However, none of the results was satisfactory.
[0008]
[Problems to be solved by the invention]
Accordingly, the main problem to be solved by the invention is that the mat base is integrated with the mat base at a predetermined position on the periphery of the mat base, and is formed with an arbitrary cross-sectional shape. The floor mat is mainly composed of the edge of the mat base and the carpet adhered to the surface of the edge. It was that it was not possible to improve.
Other problems and advantages to be solved by the invention will be clarified sequentially below.
[0009]
[Means for Solving the Problems]
As a result of examining the drawbacks of the conventional floor mat structure in order to formulate means for solving the problems, the present inventors have found the following.
[0010]
Floor mats such as entrance mats and automobile floor mats are used by simply laying them without being bonded to the floor surface so that they can be easily replaced or cleaned. When entering the room, if the center part of the floor mat is stepped on, there will be no inconvenience such as the floor mat moving and the edge warping.
[0011]
However, when entering the room, if the edge of the floor mat is stepped on directly or kicked out with a toe, the edge may warp or get caught, and the entire floor mat may move. This is mainly due to the fact that the mat base and the edge attached around the mat base have the same hardness, or if the edge has a high hardness, the impact due to the toe kicking out cannot be absorbed. is there. Therefore, by making the edge of the floor mat into a foam, the edge absorbs the impact caused by the toe kicking out, etc., and the stress does not propagate to other than the edge, thereby causing the edge to warp, Alternatively, it has been found that inconveniences such as entrainment, movement of the entire floor mat, and poor followability with the floor do not occur. Furthermore, since the edge portion is integrally formed with the mat base and is formed by molding, the edge processing step that has been conventionally required is reduced, and thus the cost can be reduced.
[0012]
Accordingly, the present invention, which is a means for solving one of the above-mentioned main problems, is integrated with the mat base at a predetermined location on the periphery of the mat base and has an arbitrary cross-sectional shape. A floor mat composed of an edge portion formed by being raised and a carpet bonded to the surface of the mat base and the edge portion, wherein the mat base has a solid structure and the inside of the edge portion is A floor mat having a foam structure.
[0013]
Furthermore, the present invention, which is a means for solving one of the above-mentioned main problems, is integrated with the mat base at a predetermined location on the periphery of the mat base and the mat base and has an arbitrary cross-sectional shape. A floor mat composed of an edge portion formed by being raised and a carpet bonded to the surface of the mat base and the edge portion, wherein the mat base has a solid structure and the inside of the edge portion is A method for producing a floor mat having a foam structure, the method comprising: molding a sheet in which a layer containing a foaming agent and a solid layer are laminated by a predetermined method; a carpet; and A step of producing a floor mat preform by laminating sheets, a foaming step of heating the floor mat preform and foaming a foaming agent in a layer containing the foaming agent, and the foaming And a pressing step of pressing the floor omat preform to form an edge and simultaneously bonding the carpet and the sheet to form the floor mat preform as an integral structure. A method for manufacturing a mat.
[0014]
In one preferred embodiment of the present invention, a foaming step of heating the floor mat preform to foam the foaming agent in the layer containing the foaming agent, and pressing the foamed floor mat preform to form the edge At the same time, the pressing step for bonding the carpet and the sheet to form the floor mat preform as an integral structure can be performed separately or simultaneously.
[0015]
In the practice of the present invention, when the foaming step and the pressing step are performed separately, the press uses a cold press. On the other hand, when performing a foaming process and a press process simultaneously, a press uses a hot press. Therefore, when a hot press is used, the product cannot be taken out immediately after pressing, and therefore a cooling step is required. Examples of the cooling method include a method of cooling the mold together with the product sandwiched after the hot pressing is completed.
In any case, the present invention includes both a method for separately performing the foaming step and the pressing step and a method for simultaneously performing the step. When implementing the present invention, which method is adopted is determined in consideration of various conditions such as the size and shape of the floor mat to be manufactured, the capability of the press to be owned, and the production efficiency.
[0016]
The main material of the mat base used in the production of the floor mat of the present invention is a thermoplastic synthetic resin such as polyvinyl chloride, rubber, a thermoplastic elastomer, or a mixture of two or more thereof. In the production of the floor mat of the present invention, the same type of main material may be used for the mat base and the foam layer inside the edge, or the main material may be changed between the mat base and the foam layer.
[0017]
The floor mat of the present invention can be manufactured in any shape. From the viewpoint of reducing the weight of automobiles in recent years, the thickness of the mat base is set in the range of 1 to 1.5 mm, but the lower limit value and the upper limit value are not limited.
[0018]
The edge part of the floor mat of the present invention is formed integrally and continuously with the mat base at the periphery of the mat base. That is, the edge portion is formed by separating the mat base into two or three layers at the rising portion of the edge portion to form a predetermined cross-sectional shape. Therefore, when the mat base has a two-layer structure, the edge is foamed on the surface in contact with the carpet. When the mat base has a three-layer structure, only the second layer of the mat base is foamed. The surfaces of the first layer and the third layer are both solid structures and form so-called skin layers.
[0019]
The expression “predetermined cross-sectional shape” used with respect to the edge of the floor mat of the present invention means that when the edge of the floor mat is cut in the width direction, the cross-section is, for example, a triangle, a quadrangle, a trapezoid, a circle, or other It has an arbitrary shape. The shape of the cross-sectional shape of the edge is a design matter determined by various conditions such as the use of the floor mat, the design, the material of the carpet, and the texture. Further, although the expansion ratio of the edge is arbitrarily determined, it is usually preferable to set in the range of 3 to 4 times, and the height of the edge is set in the range of 4 to 9 mm. And the upper limit is not limited.
[0020]
A plurality of nibs having an arbitrary shape whose width, height, pitch and the like can be freely selected can be provided on the back surface of the mat base, that is, the surface in contact with the floor surface. These nibs may have, for example, a circular or square cross-sectional shape in the width direction.
[0021]
Embodiments will be described below with reference to the accompanying drawings.
[Example 1]
1 is a cross-sectional view in the width direction of a floor mat manufactured in Example 1. FIG. In FIG. 1, 1 is a floor mat. 2 is a mat base of a solid structure, which is divided into three layers at the periphery, one layer rising at a height of 6 mm, the other layer is stretched as it is, and both layers are united at a predetermined position to form the edge 3. The extension portion 5 is formed by further extending. The edge portion 3 is filled with a foam layer 4 having a double foaming rate, and the skin is covered with a solid mat base. A trapezoidal nib 6 is formed integrally with the mat base 2 on the back surface of the mat base 2. A carpet 7 is integrally bonded to the surfaces of the mat base 2, the edge 3 and the extension 5.
[0022]
The mat base and edge foam layer formulation used in Example 1 is described below.
Matte base formulation
Component weight part SBS 100
C _a CO ₃ 25
Pigment appropriate amount [0023]
Edge foam layer formulation
Component weight part SBS 100
C _a CO ₃ 25
Pigment appropriate amount Foaming agent 2-3
[0024]
A sheet in which the first layer is molded from the above mat base compound, a second layer from the edge foam layer compound, and a third layer from the mat base compound The sheet having a three-layer structure consisting of was cut into a standard while being extruded. On the other hand, a carpet cut into a standard size is placed on the bottom of the mold, the sheets of the three-layer structure cut into the standard size are laminated, the mold is heated to about 190 degrees Celsius, and the second layer sheet has an expansion ratio of 2 Double foamed. Next, cold pressing was performed to form edges, and at the same time, the entire sheet and the carpet were bonded together to produce a predetermined floor mat.
[0025]
[Example 2]
As a sheet to be bonded to the carpet, the first layer is formed from a mat base compound having the same composition as in Example 1, and the second layer is formed from an edge foam layer composition having the same composition as in Example 1. A predetermined floor mat was manufactured by repeating the same procedure as in Example 1 except that a sheet having a two-layer structure was used and the expansion ratio was tripled.
[0026]
[Example 3]
Using the same formulation as used in Example 1, the first layer is molded from the mat base formulation, the second layer is molded from the edge foam layer formulation, and the three layers A sheet with a three-layer structure, in which the eyes were formed from a mat base formulation, was produced. This sheet and carpet are continuously laminated without being cut into regular lengths and heated to foam the second layer sheet at a foaming ratio of 2 times, and then inserted into a mold to raise and form the edge. Then, a predetermined floor mat was manufactured by cold pressing.
[0027]
[Example 4]
Using the same formulation as used in Example 1, the first layer consists of a sheet molded from the mat base formulation and the second layer consists of a sheet molded from the edge foam layer formulation 2 A layered sheet was produced. This sheet and the carpet are heated without being cut continuously and heated while being laminated, and after the second layer sheet is foamed at a foaming ratio of 2 times, the edge is raised and formed in the mold. Inserted and cold pressed to produce a predetermined floor mat.
[0028]
[Example 5]
Using the same formulation used in Example 1, the first layer is molded from the mat base formulation, the second layer is molded from the edge foam layer formulation, and 3 A sheet having a three-layer structure in which the layer was formed from a mat base compound was cut into a fixed length while being extruded. On the other hand, a carpet cut to a standard length is placed on the bottom of the mold, the sheets of the three-layer structure cut to a standard size are laminated, and the mold is heated and pressurized at about 185 degrees Celsius and a pressure of 20 to 30 kg / cm ^2. Then, the sheet of the second layer was foamed twice to form an edge portion, and at the same time, the sheet and the carpet were bonded. The mold was cooled as it was, and then the floor mat was taken out.
[0029]
[Example 6]
Using the same formulation as used in Example 1, the first layer consists of a sheet molded from the mat base formulation and the second layer consists of a sheet molded from the edge foam layer formulation 2 A layered sheet was produced. The sheet and the carpet are first laminated and then heated with a heater to foam the second layer sheet at a foaming ratio of 2 times, and then inserted into a mold to raise the edge and form a cold sheet. A predetermined floor mat was manufactured by pressing for a while.
[0030]
【The invention's effect】
As described above, the floor mat of the present invention has an edge formed integrally with a mat base made of a solid layer, and has a foamed layer inside thereof. The edge absorbs the impact and prevents the stress from propagating to other than the edge, and there is no inconvenience such as warping or entrainment of the edge. It is not displaced or moved, and it is easy to follow the floor.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of an embodiment of the invention.
[Explanation of symbols]
1 Floor mat 2 Mat base 3 Edge 4 Foam layer 5 Extension 6 Nib 7 Carpet

Claims (8)

A mat base, an edge formed integrally with the mat base at a predetermined position on a peripheral edge of the mat base, and formed with an arbitrary cross-sectional shape, and the mat base and the edge A floor mat comprising a carpet bonded to a surface, wherein the mat base has a solid structure and the inside of the edge portion has a foam structure. A mat base, an edge formed integrally with the mat base at a predetermined position on a peripheral edge of the mat base, and formed with an arbitrary cross-sectional shape, and the mat base and the edge A floor mat comprising a carpet bonded to a surface, wherein the mat base has a solid structure, and the inside of the edge has a foam structure, A method in which a sheet in which a layer containing a foaming agent and a solid layer are laminated is formed by a predetermined method; a step in which a carpet and the sheet are laminated to produce a floor mat preform; and the floor mat A foaming step of heating the preform to foam the foaming agent in the layer containing the foaming agent, and pressing the foamed floor mat preform to form an edge and Method of making a floor mat, characterized in that it mainly comprises a pressing step to bond carpet and the said sheet is an integral structure of the floor mat preform. The method for manufacturing a floor mat according to claim 2, wherein the foaming step and the pressing step are performed separately. The method for producing a floor mat according to claim 2, wherein the pressing step is performed by cold pressing. The method for producing a floor mat according to claim 2, wherein the foaming step is performed simultaneously with the pressing step. The method for producing a floor mat according to claim 5, wherein the pressing step is performed by hot pressing. The method for manufacturing a floor mat according to claim 2, wherein the sheet has a two-layer structure of a layer containing a foaming agent and a solid layer. 3. The method for manufacturing a floor mat according to claim 2, wherein the sheet has a three-layer structure in which solid layers are laminated on both upper and lower sides through a layer containing a foaming agent.

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