JP4614665B2 - floor mat - Google Patents

Description

  The present invention relates to a floor mat that can be used for automobiles, residences, or offices. In particular, the present invention relates to a floor mat that can be suitably used for automobiles.

  Conventionally, a floor mat has been laid so that the floor in an automobile interior is not soiled by dirt or mud adhering to shoes or the like.

  As such a floor mat for automobiles, a carpet layer provided with a pile and a backing layer that supports the carpet layer is excellent in design and has a high-class feeling, and thus is preferably used. . In such a floor mat, an overlock process and / or a taping process is performed on the peripheral part of the floor mat in order to prevent the pile at the peripheral part of the carpet constituting the floor mat from falling off and to create a sense of quality. What performed (edge processing) is common. Actually, the applicant of the present application has also proposed a floor mat subjected to both overlock processing and taping processing (see Patent Document 1 and FIG. 2).

  However, the floor mat M subjected to such edge treatments 1 and 2 is excellent in design and high-quality when the floor mat M alone is used. However, when the floor mat M is laid on a car floor, The peripheral edge E subjected to the edge processing 1 and 2 of M is conspicuous, and the sense of unity with the passenger compartment may be impaired. In particular, the higher the floor mat, the longer the length of the hair pile of the carpet pile P constituting the floor mat M, but the edge processing 1 and 2 must be performed with a wide width from the periphery Ea of the floor mat M. Since the pile P cannot be prevented from falling out, the contradiction that the problem becomes remarkable despite the use of the carpet made of the pile P having a long bristle to enhance the sense of quality. The situation was happening.

  On the other hand, the applicant of the present application has proposed a floor mat that has a carpet layer and a backing layer, has not been subjected to edge processing, and is coated with a carpet layer pile (Patent Document 2, Patent). (Refer to Document 3, in order of FIG. 3 and FIG. 4). These floor mats M can be basically manufactured by a temporary pressing step, a cutting step, and a main pressing step. However, since the carpet constituting the floor mat M always has an eye direction, the pile P tends to fall in the forward direction but not easily in the reverse direction due to the pressure in the pressing process. There was a tendency that the covering state of the peripheral edge E with the pile P was likely to be non-uniform and the designability was likely to be poor.

Japanese Utility Model Publication No. 4-54024 (Scope of request for utility model registration) JP-A-11-268568 (Claim 3, Claim 4, etc.) JP 2000-93285 A (Claim 3, paragraph number 0044, etc.)

  An object of the present invention is to provide a floor mat that is excellent in design, such as a pile that does not fall off, can be in harmony with the surrounding environment during use, and can create a high-class feeling.

The invention according to claim 1 of the present invention is a floor mat provided with a carpet layer provided with a pile and a backing layer that supports the carpet layer, and the root of the pile at the periphery of the floor mat is a taping process. Or , the pile is tilted toward the periphery of the floor mat by being fixed in the direction of the backing layer by overlock processing , and the periphery of the floor mat that has been taped or overlocked is covered by the fallen pile. Is a floor mat. " In this way, the pile at the periphery of the floor mat is fixed at the root by taping or overlock processing, so that the pile does not fall off and is not affected by the direction of the carpet eyes. When the pile falls to the edge and the periphery of the floor mat that has been taped or overlocked is covered by the fallen pile, the periphery of the floor mat that has been taped or overlocked is inconspicuous, and the floor mat is laid It is excellent in design, in harmony with the surrounding environment and creating a sense of quality.
Furthermore, since the floor mat is fixed by taping or overlock as described above, the periphery of the floor mat is aligned even when viewed from the backing layer side. Easy to demonstrate. In addition, since it is fixed simply by sewing and is not heated, the pile constituting the carpet is not damaged, such as being crushed, and thus it is excellent in design.

The invention according to claim 2 of the present invention, "as fibers constituting the pile, characterized in that it contains modified cross-section fibers, floor mat of claim 1 Symbol placement" is. A pile including such atypical cross-section fibers tends to be bulky and easily collapses, so that the peripheral edge of the floor mat is easily covered. Therefore, it is a floor mat excellent in design that can harmonize with the surrounding environment and create a sense of quality.

  The floor mat of the present invention is excellent in design properties, in which the pile does not fall off, can be in harmony with the surrounding environment at the time of use, and can bring out a high-class feeling.

  The floor mat of the present invention will be described with reference to FIG. 1, which is a partially enlarged sectional view in the thickness direction at the peripheral edge of the floor mat of the present invention. In addition, the same code | symbol is attached | subjected about the same member as the conventional floor mat.

  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, a first backing layer K1 that supports the carpet layer C, and a second backing layer K2. C, the tape 1 disposed so as to cover the peripheral edge E of the first backing layer K1 and the second backing layer K2, and the tape 1 are fixed, and the root of the pile Pe at the peripheral edge E of the floor mat M is It is comprised from the 1st backing layer K1 and the suture thread 1a fixed to the 2nd backing layer K2 direction. In such a floor mat M, since the root of the pile Pe at the peripheral edge E of the floor mat M is fixed by the suture thread 1a, the pile Pe does not fall off at the peripheral edge E of the floor mat M. Further, since the root of the pile Pe at the peripheral edge E of the floor mat M is forcibly fixed in the direction of the first backing layer K1 and the second backing layer K2 by the suture thread 1a, regardless of the carpet eye direction, Since the pile Pe uniformly falls to the peripheral edge Ea side of the floor mat M and the peripheral edge portion E of the floor mat M is covered with the pile Pe, the peripheral edge portion E of the floor mat M is not conspicuous and the floor mat M is laid. It has a good design that can sometimes create a sense of quality in harmony with the surrounding environment.

  The carpet which comprises the carpet layer C of the floor mat M of this invention should just be equipped with the pile P, and even if the pile P is fixed to the primary base fabric B like FIG. It may be fixed to a thread. 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, when the fiber which comprises the pile P contains atypical cross-section fiber, the pile P is easy to be bulky, the pile Pe at the peripheral edge E is easy to fall down, and the peripheral edge E of the floor mat M is easily covered. Is preferred. 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 P is composed of the atypical cross-section fiber, and 70 mass% or more is the atypical cross-section. More preferably, it is composed of fibers, and most preferably 100 mass% is composed of atypical cross-section fibers.

In addition to the pile P including the irregular cross-section fibers as described above, the pile P is easy to open (40 to 200 T / m), the pile P is large (1000 g / m ² or more), and the specific gravity is 0.9. Pile P made of ~ 1.0 g / cm ³ ) fiber (for example, polypropylene fiber) is suitable for use because it is easy to be bulky, the pile Pe is easy to collapse, and the peripheral edge E of the floor mat M is easily covered. it can.

  Note that the length L of the hair p of the pile P depends on the fixing position of the pile Pe at the peripheral edge E by the suture thread 1a or the like, but it has a high-class feeling and is excellent in design, and the peripheral edge of the floor mat M It is preferably 5 mm or more so that E can be easily covered. In addition, although the upper limit of the bristle leg length L of the pile P is not specifically limited, it is realistic that it is 20 mm or less. This “pile hair leg length” refers to the protruding length of the pile from the primary base fabric or thread (L in FIG. 1).

  The floor mat M of the present invention is provided with the backing layers K1 and K2 for supporting the carpet layer C as described above, and the backing layers K1 and K2 provide durability, sound insulation, sound absorption, anti-slip, and water insulation. At least one function such as vibration damping is imparted to the floor mat M. In FIG. 1, a first backing layer K1 and a second backing layer K2 are provided. Thus, the backing layer need not be a single layer, and may be provided with two or more layers.

Specific examples of materials that can constitute the backing layers K1 and K2 include (1) a thermoplastic resin sheet, (2) a thermoplastic elastomer sheet, (3) a thermosetting resin sheet, (4) a natural or synthetic rubber sheet, (5) Ultrafine nonwoven fabric containing ultrafine fibers having a fiber diameter of 10 μm or less, generated by dividing the split fibers with a fluid flow such as a water stream, (6) Fibers generated by extracting and removing the resin component of the split fibers An ultrafine nonwoven fabric containing ultrafine fibers having a diameter of 10 μm or less, (7) an ultrafine nonwoven fabric comprising ultrafine fibers having a fiber diameter of 10 μm or less, formed by a melt blow method, and (8) a thickness (at 10 g load per cm ² ) of 1 mm or more. Bulky nonwoven fabrics (needle punched nonwoven fabrics, heat fusion nonwoven fabrics, melt blown nonwoven fabrics having a fineness of 6.6 dtex or more), (9) foams, etc. Can be combined above.

  In the floor mat of the present invention, the root of the pile at the peripheral edge E of the floor mat is fixed in the backing layer direction by means other than the primary base fabric or the yarn constituting the carpet. Although the primary base fabric or yarn constituting the carpet can project the pile in a right angle direction, there is no action of deflecting the pile in the direction of the peripheral edge Ea of the floor mat, so that other than the primary base fabric or yarn constituting the carpet. By this means, the pile base is fixed in the direction of the backing layer. In FIG. 1, the tape 1 is disposed so as to cover the peripheral edge E of the carpet layer C, the first backing layer K1, and the second backing layer K2, and the tape 1 and the pile Pe on the peripheral edge E of the floor mat M are arranged. The root is fixed by a suture thread 1a stitched in the direction of the first backing layer K1 and the second backing layer K2. According to the so-called taping process using the tape 1 and the suture thread 1a, since the peripheral edge Ea of the floor mat M is aligned, the floor mat M is in close contact with the surrounding environment, and the performance of the floor mat M is easily exhibited. In addition, the floor mat M can be a floor mat M that is not damaged by the pile P being crushed because it is fixed simply by sewing and is not heated. Unlike Fig. 1, when the pile root at the periphery of the floor mat is sewn and fixed in the direction of the backing layer by overlock processing, the periphery of the floor mat is aligned and the periphery of the floor mat is the same as taping. The floor mat is easy to exhibit the performance of the floor mat in close contact with the environment, is not heated, and does not damage the pile. Therefore, the floor mat can be excellent in design. If the influence of heat can be tolerated, the base of the pile can be heat-sealed and fused and fixed in the direction of the backing layer.

  The distance (d in FIG. 1) from the periphery Ea of the floor mat M to the place where the base of the pile Pe is fixed is not particularly limited, but the pile Pe covers the periphery E of the floor mat M. And it is preferable that it is 10 mm or less so that the peripheral part E may not stand out. On the other hand, it is preferably 3 mm or more so that the pile Pe can be prevented from falling off. In addition, the pile foot length (L) of the pile P is longer than the distance (d) from the periphery Ea of the floor mat M to the place where the base of the pile Pe is fixed (L / d> 1). Since the peripheral edge E of the floor mat M can be reliably covered by the fall of the pile Pe, this is a preferred embodiment, more preferably L / d ≧ 1.5, and even more preferably L / d ≧ 1. .8.

  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, but the peripheral edge of the floor mat is not conspicuous by the pile with the root fixed. As long as it can be covered, it may be piles in the second and subsequent rows from the periphery E of the floor mat. In addition, “root” means a position where the periphery of the floor mat can be concealed so that the periphery of the floor mat is not conspicuous because the pile is fixed. In general, however, it is a range from the end of the primary base fabric surface side or the yarn surface side of the pile to a position of about 3 mm in the protruding direction of the pile. 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.

  The floor mat of the present invention can be the same as the conventional floor mat except for the above-described explanation. For example, it is possible to connect floor mats by providing a number of protrusions on the back side of the backing layer, applying adhesive, or laminating urethane foam to prevent slipping, attaching hook-and-loop fasteners and hooks, etc. You may do it.

  The floor mat M as shown in FIG. 1 can be manufactured as follows, for example. First, a carpet having a desired shape, a first backing material having a desired shape, a second backing material having a desired shape, a tape, and a suture are prepared. Then, after laminating the second backing material, the first backing material and the carpet in order, using the sewing machine while applying the tape from the peripheral edge E of the second backing material to the base of the pile Pe at the peripheral edge E of the carpet The base of the pile Pe at the peripheral edge E of the tape and the carpet can be sewn in the direction of the backing layers K1 and K2 with the suture thread. In addition, as the sewing machine, use a primary base fabric B of the carpet or a jig provided to separate the yarn and the pile Pe, or press the primary base fabric B of the carpet or the yarn and the pile Pe separately from the sewing machine. It is preferable to fix the root of the pile Pe by taking a means for dividing. In addition to simply laminating the second backing material, the first backing material and the carpet, a hot melt sheet, a hot melt resin, or an adhesive is interposed between these materials. It is desirable to eliminate the deviation and improve the form stability of the floor mat M.

  The floor mat M of the present invention is excellent in design such that the pile Pe does not fall off, can be harmonized with the surrounding environment at the time of use, and can bring out a high-class feeling. It can be suitably used as a floor mat for automobiles, and in particular, when used for automobiles, it is of high quality and can be made into a car interior full of luxury in harmony with interior materials other than the floor mat.

  Examples of the present invention will be described below, but the present invention is not limited to the following examples.

Example 1
Pile layer (weight per unit: 1800 g / m ² , number of twists: 160 T / m, hair length: 14 mm) made of nylon fibers having a Y-shaped irregular cross section, and a spunbond nonwoven fabric made of polyester fiber that supports the pile layer ( A tufted carpet having a basis weight of 120 g / m ² , a primary base fabric, and a latex having styrene-butadiene rubber as a main component applied to the back surface of the primary base fabric (dry mass: 240 g / m ² ) was prepared.

Also, a backing material was prepared by frame-laminating urethane foam (weight per unit: 100 g / m ² , thickness: 2 mm) on a polyester needle punched nonwoven fabric (per unit: 400 g / m ² , thickness: 3 mm).

Next, the back surface of the tufted carpet is prepared by mixing a styrene-butadiene rubber latex and a natural rubber latex at a mass ratio of 30:70 and foaming the mixed rubber latex foamed by mechanical foaming to a basis weight of 300 g / m ^2. (Latex coated surface) Before the mixed rubber latex is dried, the polyester needle punched nonwoven fabric of the backing material is overlaid so as to come into contact with the mixed rubber latex. And the backing material were integrated to produce a composite.

  Next, the composite is cut into the shape of a floor mat for an automobile, a floor mat precursor is formed, and then the pile yarn and the primary base fabric are pressed and separated from the peripheral edge of the urethane foam to the peripheral edge of the tufted carpet. While the tape was applied to the base of the pile, the floor mat was manufactured by sewing the tape and the base of the pile in a direction perpendicular to the polyester needle punched nonwoven fabric with a sewing thread using a sewing machine. The distance (d) from the periphery of the floor mat to the place where the pile root was fixed was 6 mm, and L / d was 2.3. When this floor mat is laid in the car interior, the tape on the periphery of the floor mat is covered with a pile and cannot be confirmed, and it is possible to create a sense of quality in harmony with the car interior. It was excellent in properties. Moreover, the piles did not fall off when the floor mat was handled.

(Example 2)
Pile layer (weight per unit: 1800 g / m ² , number of twists: 160 T / m, hair length: 14 mm) made of nylon hollow fiber having a Y-shaped irregular cross section, and a polyester fiber spunbond nonwoven fabric that supports the pile layer (Weight per unit area: 120 g / m ² , primary base fabric), and a tufted carpet in which a latex mainly composed of styrene-butadiene rubber was applied to the back surface of the primary base fabric (dry mass: 240 g / m ² ) was used. A floor mat was produced in the same manner as in Example 1 except that. The distance (d) from the periphery of the floor mat to the place where the pile root was fixed was 6 mm, and L / d was 2.3. When this floor mat is laid in the car interior, the tape on the periphery of the floor mat is covered with a pile and cannot be confirmed, and it is possible to create a sense of quality in harmony with the car interior. It was excellent in properties. Moreover, the piles did not fall off when the floor mat was handled.

(Comparative Example 1)
After the floor mat precursor was formed in exactly the same manner as in Example 1, an overlock process (sewing width: 9 mm) was performed while winding a pile around the periphery of the floor mat precursor to produce a floor mat. When this floor mat was laid in the automobile room, the overlock yarn at the peripheral edge of the floor mat became conspicuous and could not be matched with the automobile room.

(Comparative Example 2)
A floor mat precursor was formed in exactly the same manner as in Example 1, and then a taping process (tape width: 13 mm) was performed while winding a pile around the periphery of the floor mat precursor to produce a floor mat. When this floor mat was laid in the automobile room, the tape at the peripheral edge of the floor mat was conspicuous and could not be harmonized with the automobile room.

Partial enlarged sectional view in the thickness direction at the periphery of the floor mat of the present invention Partial enlarged sectional view in the thickness direction at the periphery of a conventional floor mat Partial enlarged sectional view in the thickness direction at the periphery of another conventional floor mat Partial enlarged cross-sectional view in the thickness direction at the peripheral edge of still another conventional floor mat

Explanation of symbols

M Floor mat P Pile Pe Pile at the periphery of the floor mat B Primary base fabric C Carpet layer L Pile hair length K Backing layer K1 First backing layer K2 Second backing layer E Perimeter Ea Perimeter d From the periphery of the floor mat Distance to the place where the pile base is fixed 1 Tape 1a Suture 2 Overlock thread

Claims (2)

A floor mat that has a carpet layer with pile and a backing layer that supports the carpet layer, and the root of the pile at the periphery of the floor mat is fixed in the direction of the backing layer by taping or overlocking. The floor mat is characterized in that the pile falls to the periphery of the floor mat, and the periphery of the floor mat that has been taped or overlocked is covered by the fallen pile . As the fibers constituting the pile, characterized in that it contains modified cross-section fibers, 1 Symbol placement of the floor mat according to claim.

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