JP4709624B2 - Molded carpet for vehicle and method for producing molded carpet for vehicle - Google Patents

Description

  The present invention relates to a molded carpet for a vehicle formed into a shape along the shape of the upper surface of a floor panel of a vehicle body, and a method for manufacturing the molded carpet for a vehicle.

  Conventionally, an automobile carpet 1 as shown in FIG. 16 is known (see, for example, Patent Document 1).

  First, the configuration of the automobile carpet 1 will be described with reference to FIGS. 16 and 17.

  As shown in FIG. 16, the floor panel 2 of the vehicle body includes a floor tunnel 2a that is formed to project upward in the center in the vehicle width direction, flat portions 2b and 2b on the left and right sides of the floor tunnel 2a, the floor tunnel 2a, Each of the flat portions 2b and 2b has a boundary portion 2c and 2c at each boundary.

  In addition, the carpet 1 for an automobile includes a molded felt 3 that is formed in advance along the shape of the upper surface of the floor panel 2 of the vehicle body, and a heater duct 4 that is disposed on the molded felt 3 in the vicinity of the boundaries 2c and 2c. , 4 and the carpet 5 formed along the shape of the upper surface of the molded felt 3 and the heater ducts 4, 4.

  The carpet 5 is formed to have a carpet body 5a and a resin layer 5b coated in advance on the back side of the carpet body 5a.

  Moreover, the carpet 5 is thermally welded to the upper surfaces of the molded felt 3 and the heater ducts 4 and 4 by melting the resin layer 5b of the carpet 5.

  Therefore, the carpet 1 for an automobile includes a carpet 5 having a resin layer 5b provided on the back surface, a molded felt 3 welded to the resin layer 5b, and a heater duct interposed between the carpet 5 and the molded felt 3. 4, 4 etc. are integrally formed.

  Next, the manufacturing method and operation of this conventional automobile carpet 1 will be described.

  As shown in FIG. 17, the upper surface shape of the lower die 6 of the press device is formed in a shape substantially along the upper surface shape of the floor panel 2 of the vehicle body as shown in FIG. 16.

  The lower mold 6 includes a projecting portion 6a projecting upward from the center of the lower mold 6, plane portions 6b and 6b on the left and right sides of the projecting portion 6a, and the projecting portion 6a and the planar portions 6b and 6b. Boundary portions 6c, 6c and the like are provided at each boundary.

  First, on the upper surface of the lower mold 6 of this press apparatus, the molding felt 3 previously molded into the upper surface shape of the lower mold 6 is laid.

  The heater ducts 4 and 4 are arranged on the molded felt 3 in the vicinity of the boundary portions 6c and 6c, and the resin layer 5b on the back surface is heated between the upper surface of the molded felt 3 and the heater ducts 4 and 4 and the upper mold 7. Insert the melted carpet 5.

  Further, as shown in FIG. 17, the upper die 7 is lowered to press the carpet 5, and the carpet 5, the heater ducts 4, 4 are formed by the molten resin layer 5 b on the back surface of the carpet 5. The formed felt 3 is welded.

  For this reason, as shown in FIG. 16, the carpet 1 for an automobile includes a carpet 5, heater ducts 4, 4, a molded felt 3, and the like that are integrally formed, and follows the shape of the upper surface of the floor panel 2 of the vehicle body. It is molded into a different shape.

Accordingly, when the automobile carpet 1 is laid on the floor panel 2 of the vehicle body, the heater ducts 4 and 4 can be disposed in the vicinity of the boundary portions 2c and 2c on the floor panel 2.
Japanese Utility Model Publication No. 64-7040 (2nd to 6th pages, FIG. 1 or FIG. 2)

  However, in the conventional automobile carpet 1, the molded felt 3 provided around the heater duct 4 is thin and weak in elasticity. Therefore, the heater duct 4 may be deformed or damaged by the force applied from the upper side of the carpet body 5a. It was.

  Therefore, in the present invention, in order to prevent deformation or breakage of the duct, when the carpet body is laid on the floor panel, the duct and the cushion spacer having a height higher than the height of the duct are arranged side by side. A duct is joined to the back side of the carpet body, and a cushion spacer is joined integrally to the remaining portion where the duct is not joined.

  Provided is a molded carpet for a vehicle that can prevent deformation or breakage of the duct due to a force applied from the upper part of the carpet body by the cushion spacer integrally provided in the duct, and a method for manufacturing the molded carpet for the vehicle. It is an issue.

In order to achieve the above object, according to the first aspect of the present invention, a carpet body formed along the shape of the upper surface of the floor panel is laid on the floor panel of the vehicle body, A molded carpet for a vehicle having a carpet body with a duct and a cushion spacer interposed therebetween,
The carpet is bonded to the back surface side of the carpet body in advance, and the cushion spacer having a height higher than the height of the duct is integrally bonded to the remaining portion where the duct is not bonded. When laying, the vehicle is characterized by a molded carpet for a vehicle in which the duct and the cushion spacer are arranged side by side on the floor panel.

  According to a second aspect of the present invention, there is provided a thermoplastic resin layer in which the duct and the cushion spacer are welded by heat and pressure molding on the back side of the carpet body. It features a molded carpet for vehicles.

  According to a third aspect of the present invention, the duct is divided into an upper member and a lower member, and at least the lower member has a flange portion joined to the upper member on an outer side edge portion. The molded carpet for a vehicle according to claim 1 or 2 formed in a direction.

  Furthermore, in the invention described in claim 4, the flange portion of the upper member or a part of the back surface side of the upper member is joined to the flange portion of the lower member, and the upper member is predetermined. The molded carpet for a vehicle according to claim 3 having surface rigidity.

  According to a fifth aspect of the present invention, in the vehicle molding according to any one of the first to fourth aspects, the flange portion of the lower member is locked to the upper surface of the side edge portion of the cushion spacer. It features a carpet.

  According to a sixth aspect of the present invention, in the vehicle according to any one of the third to fifth aspects, the upper surface of the upper member and the upper surface of the cushion spacer are substantially flush with each other in the vehicle vertical direction. It features a molded carpet.

  Furthermore, in the invention described in claim 7, the flange portion of the lower member and the upper member joined to the flange portion are provided between the upper surface of the side edge of the cushion spacer and the back surface of the carpet body. A molded carpet for a vehicle according to any one of claims 1 to 6, which is sandwiched between the two.

  According to an eighth aspect of the present invention, a carpet opening is formed in the vehicle interior side of the carpet body so as to expose the air outlet formed at the end of the duct to the space in the vehicle interior. The molded carpet for vehicles according to claim 1, wherein the periphery of the carpet opening is in close contact with the duct.

  According to a ninth aspect of the present invention, there is provided a front end of a vehicle option mat on the front side of a vehicle by means of a step provided on the lower member below the air outlet portion formed at the end of the duct. The molded carpet for a vehicle according to claim 8, wherein the portion is locked.

  Furthermore, the invention described in claim 10 is characterized by the molded carpet for vehicles according to any one of claims 1 to 9, wherein a spacer member is disposed between the duct and the floor panel. It is said.

The invention described in claim 11 includes the step of arranging the cushion spacer and the duct at a predetermined position of the lower mold corresponding to the floor panel, and the carpet body heated above the lower mold. A step of arranging
The upper mold corresponding to the lower mold and the lower mold are pressurized, and the duct and the cushion spacer are joined to the back side of the carpet body, and the carpet body follows the shape of the floor panel. The method for producing a molded carpet for a vehicle according to claim 1, further comprising a step of forming into a shape.

  Further, in the invention described in claim 12, the joined flange portion of the lower member of the duct is locked by the cushion spacer so that the lower side of the lower member and the lower part of the press device are engaged. A gap is provided between the mold and the upper surface of the upper member and the upper surface of the cushion spacer so as to be substantially flush with each other in the vertical direction. The method for producing a molded carpet for a vehicle according to claim 11, wherein the pressure by heat and pressure molding is applied substantially uniformly to the upper surface of the member and the upper surface of the cushion spacer.

  Furthermore, in the invention described in claim 13, by dividing the duct into the upper member and the lower member and forming the duct, the duct is formed by the upper member and the lower member, respectively. 13. The method for producing a molded carpet for a vehicle according to claim 11 or 12, wherein the duct can be given a certain strength because it can be performed individually.

In the invention described in claim 14, the cushion is divided into the upper member and the lower member, and the cushion spacer and the upper member are arranged at predetermined positions of the lower mold corresponding to the floor panel. Arranging the heated carpet body on the upper side of the lower mold, and
The upper mold corresponding to the lower mold and the lower mold are pressed to join the upper body member and the cushion spacer to the carpet body, and the carpet body is shaped according to the shape of the floor panel. Molding process;
The method for producing a molded carpet for a vehicle according to claim 11, further comprising the step of joining the lower member to the upper member joined to the back side of the carpet body.

According to the first aspect of the present invention configured as described above, the carpet body is formed along the shape of the upper surface of the floor panel of the vehicle body, and the duct is formed on the back side of the carpet body. In order to be integrally joined with the cushion spacer having a height higher than the height of the duct,
When the carpet body is laid on the floor panel, the duct and the cushion spacer are arranged in a predetermined position.

  Therefore, the carpet body, the cushion spacer, and the duct can be arranged together in one step of installing the molded carpet for a vehicle on the floor panel of the vehicle body.

  For this reason, the number of steps in the manufacturing process can be reduced, and an increase in manufacturing cost can be suppressed.

  And since the said duct is arrange | positioned in the state supported by the said cushion spacer higher than the height of the said duct via the said carpet main body, this duct can be arrange | positioned in the stable state. it can.

  Further, the force applied to the duct because the force applied from above the position where the duct is disposed is dispersed by the elasticity of the cushion spacer having a height higher than the height of the duct. Is relaxed and the duct is less likely to be deformed or damaged.

  Furthermore, since there is no space between the duct and the carpet body, the generation of air conditioning noise due to resonance or the like can be suppressed.

  Since the back surface of the carpet body is joined to the top surface of the duct in a planar shape, the surface of the carpet body at the portion joined to the top surface of the duct becomes uniform, and the surface of the carpet body is corrugated. No hit occurs.

  According to the second aspect of the present invention, the resin layer of the thermoplastic resin provided for molding the carpet main body welds the duct and the cushion spacer to the back side of the carpet main body. Therefore, the molding agent for the carpet main body and the welding agent for the duct and the cushion spacer are used in common, and the number of members used for manufacturing is reduced, so that an increase in manufacturing cost can be suppressed.

Further, according to a third aspect of the present invention, the duct is divided into an upper member and a lower member, and at least the lower member is provided with a flange portion, and the lower member and the upper member are arranged. To join and form the duct,
Compared to conventional cylindrical ducts, the shape of the upper and lower members of the duct is simplified, and molding such as pressing is possible, increasing the degree of freedom in setting the material of the duct. To do.

  And since press working becomes possible, the mold of the press apparatus can be cooled with water, and the time of the forming process can be shortened.

  Furthermore, as compared to blow molding, the thickness of the duct member can be selected from any material and thickness for each member, so the strength of the upper and lower members of the duct can be set to the desired strength. become.

  As described above, since there is a degree of freedom in setting the strength, the upper member can be used as a reinforcing member for the floor of the passenger compartment.

  Further, for this reason, when the carpet body, the duct, and the cushion spacer are integrally formed, the strength of the duct with respect to the pressure of the heat and pressure forming can be set to a desired strength.

Moreover, the thing of Claim 4 of this invention forms the said duct which gave predetermined | prescribed surface rigidity to the said upper member,
With respect to the force applied from the upper side of the position where the duct is disposed, the duct can be hardly deformed or damaged.

And since the thing of Claim 5 of this invention has latched the flange part of the said lower side member on the side edge part upper surface of the said cushion spacer,
The elasticity of the cushion spacer acts on the force applied from the upper side of the position where the duct is disposed, in substantially the same manner as the portion where the duct is not disposed.

  In addition, the force applied to the duct is reduced by the elasticity of the cushion spacer and the force applied to the force applied from above the position where the duct is disposed, so that the duct is deformed or deformed. Can be hard to break.

And since the thing of Claim 6 of this invention makes the upper surface of the said upper side member, and the upper surface of the said cushion spacer substantially the same in the vehicle up-down direction,
Uniformity of the upper surface of the carpet body is maintained between the portion where the duct is disposed and the portion where the duct is not disposed, and the carpet body is free of undulations and has a good appearance.

Moreover, the thing of Claim 7 of this invention is the flange part of the said lower side member, and the said upper side member joined with this flange part, The side edge part upper surface of the said cushion spacer, The back surface of the said carpet main body, To hold it between
The duct is clamped in a stable state, and further air leakage from the joint portion between the upper member and the lower member of the duct can be reduced.

Furthermore, the thing of Claim 8 of this invention is because the periphery of the said carpet opening part is closely_contact | adhered with the edge part of the said duct,
When finishing by attaching a panel or the like to the air outlet, the mounting work becomes easy and the finish looks good.

And the thing of Claim 9 of this invention is a vehicle front of the said option mat for vehicles by the level | step difference provided in the said lower member on the lower side of the blower outlet part formed in the edge part of the said duct. Because the front end of
When this option mat is laid in the vehicle compartment, the orientation of the option mat is good.

Moreover, in order to arrange | position the said spacer member between the said duct and the said floor panel, the thing of Claim 10 of this invention,
Generation of noise due to contact between the duct and the floor panel can be prevented.

  Furthermore, the duct and the floor panel are not in direct contact with the force applied from above the position where the duct is disposed, so that the duct is less likely to be deformed or damaged.

  And since the said spacer member which has heat insulation is interposed between the said floor panel with high heat conductivity formed with the metal etc., and the said duct, the heat insulation of this duct improves.

Moreover, since the thing of Claim 11 of this invention performs the shaping | molding process of the said carpet main body, and the joining process of the said duct and the said cushion spacer to this carpet main body,
The number of work processes is reduced, work efficiency is increased, and an increase in manufacturing cost is suppressed.

  Further, since the cushion spacer is arranged on the lower mold in advance, when the duct is arranged, the orientation of the duct is good on the lower mold.

Further, according to the twelfth aspect of the present invention, the flange portion of the lower member of the duct is locked by the cushion spacer, and further, the lower side of the lower member, and the lower die of the press device, In order to weld to the surface of the resin layer so that the upper surface of the upper member and the upper surface of the cushion spacer are substantially flush with each other in the vertical direction.
Since the carpet body is pressed against the upper surface of the upper member and the upper surface of the cushion spacer with equal pressure, the upper surface of the upper member, the upper surface of the cushion spacer, and the carpet body can be welded uniformly. .

  In addition, since a gap is provided between the lower side of the lower member and the lower mold of the press device, the cushion spacers on both sides of the duct are elastically pressed during pressurization by the press device. The lower member of the duct is deformed and does not come into contact with the lower mold of the press device, so that the duct can be prevented from being deformed or broken by the pressure of the heat and pressure molding.

  Further, according to the thirteenth aspect of the present invention, by dividing the duct into the upper member and the lower member and forming the duct, the duct is formed by the upper member and the lower member. Each can be done individually.

  For this reason, since the molding shape of the upper member and the lower member of the duct is simpler than that of the conventional cylindrical duct, it is possible to perform molding such as press working, and the material of the duct member, etc. The degree of freedom of setting increases.

  And since press working becomes possible, the mold of the press apparatus can be cooled with water, and the time of the forming process can be shortened.

  Furthermore, the plate thickness of the duct member can be selected from any material and thickness for each member as compared to blow molding, so the strength of the upper and lower members of the duct can be set to a desired strength. It becomes possible.

  For this reason, the said upper side member can be used as a reinforcement member of the floor of a vehicle interior.

  Furthermore, for this reason, when the carpet body, the duct and the cushion spacer are integrally formed, the duct has a strength to prevent deformation or breakage of the duct against the pressure of heat and pressure molding. The desired strength can be set.

According to a fourteenth aspect of the present invention, the molding process of the carpet body and the joining process of the upper member and the cushion spacer to the carpet body are performed in one process, and then the back surface of the carpet body. In order to join the lower member to the upper member joined to
The degree of freedom in setting the material of the upper member and the lower member increases. For this reason, for example, an increase in cost can be suppressed by using iron etc. for this upper member.

  Next, based on FIG. 1 thru | or FIG. 15, the molded carpet for vehicles of the best embodiment for implementing this invention and its manufacturing method are demonstrated.

(Configuration of molded carpet for vehicle of Example 1)
First, a molded carpet for a vehicle according to Embodiment 1 of the present invention will be described.

  As shown in FIGS. 1 and 2, the molded carpet 11 for a vehicle is laid on a floor panel 12 of the vehicle body.

  The floor panel 12 of the vehicle body is provided with a floor tunnel portion 13 projecting upward at the center in the vehicle width direction. The floor tunnel portion 13 includes an upper surface portion 13a and side surface portions 13b and 13b. Have.

  Furthermore, the floor panel 12 is formed with flat portions 13 c and 13 c on the left and right sides of the floor tunnel portion 13.

  Further, as shown in FIGS. 3 and 4, the molded carpet 11 for a vehicle includes a carpet body 17a, a resin layer 17b of a thermoplastic resin formed in advance on the back surface side of the carpet body 17a, and heat and pressure molding. At this time, the duct 14 and the cushion spacer 15 are welded to the resin layer 17b.

  As shown in FIG. 2, the duct 14 is divided into an upper member 27 and a lower member 19, and the upper member 27 is formed of a flat plate member 18, a reinforcing member 21, and the like. ing.

  A duct 14 is welded to the rear surface of the carpet body 17a in advance on the molded carpet 11 for the vehicle, and a cushion spacer 15 having a height higher than the height of the duct 14 is formed on the remaining portion where the duct 14 is not welded. When the carpet body 17a is laid, the duct 14 and the cushion spacer 15 are arranged side by side on the floor panel 12.

  Further, as shown in FIGS. 1 to 8, a spacer member 16 is disposed between the floor panel 12 and the duct 14.

  3 and 4, the duct 14 is divided into a flat plate member 18 and a lower member 19, and the lower member 19 has flange portions 19 a and 19 a joined to the flat plate member 18. Is formed on the upper end of the side edge of the lower member 19 in the outward direction.

  Further, as shown in FIGS. 3 and 4, the duct 14 disposed in the flat portions 13 c and 13 c in FIG. 1 is substantially the same in cross section as the side end portions 18 a and 18 a of the flat plate-like member 18. The flanges 19a, 19a of the lower hat-shaped lower member 19 are joined in advance.

  Each of the joint portions 20a, 20a of the duct 14 in which the side end portions 18a, 18a and the flange portions 19a, 19a are joined is formed of the cushion spacers 15, 15 arranged in parallel near the both sides of the duct 14. The upper surface 18b of the flat plate member 18 and the upper surfaces 15a and 15a of the cushion spacers 15 and 15 are substantially flush with each other in the vehicle up-and-down direction while being locked by the side edge upper surfaces 15b and 15b. Thus, it is welded to the resin layer 17b on the back side of the carpet body 17a.

  For this reason, the joint portions 20a and 20a of the duct 14 are sandwiched between the resin layer 17b on the back surface side of the carpet body 17a and the side edge upper surfaces 15b and 15b of the cushion spacers 15 and 15, respectively.

  Thus, the molded carpet 11 for a vehicle is integrally formed by welding the carpet body 17a, the duct 14, and the cushion spacer 15 to the back side of the carpet body 17a.

  Further, the duct 14 disposed on the side surface portions 13b and 13b of the floor tunnel portion 13 shown in FIGS. 1 and 2 is a flat plate having a predetermined surface rigidity, as shown in FIGS. The joint surfaces 21a and 21a of the reinforcing member 21 and the flange portions 19a and 19a of the lower member 19 of the substantially reverse hat-shaped cross section are joined in advance.

  The side edges of the cushion spacers 15, 15 in which the flange portions 19 a, 19 a of the lower member 19 and the side portions 21 c, 21 c of the flat plate-like reinforcing member 21 are juxtaposed adjacent to both sides of the duct 14. The upper surface 21b of the reinforcing member 21 and the upper surfaces 15a and 15a of the cushion spacers 15 and 15 are substantially flush with each other while being locked by the upper surfaces 15b and 15b. The resin layer 17b is welded.

  Therefore, the flange portions 19a and 19a of the lower member 19 and the side portions 21c and 21c of the flat reinforcing member 21 are side edges of the resin layer 17b on the back surface side of the carpet body 17a and the cushion spacers 15 and 15, respectively. It is clamped between the part upper surfaces 15b and 15b.

  Further, as shown in FIGS. 9 and 10, the air outlet 14 b provided at the end 14 a of the duct 14 has an extended portion that extends outward from the end 14 a of the lower member 19. 19b is provided, and the resin layer 17b on the back surface side of the carpet body 17a is welded to the upper surface 19c of the extended portion 19b from the upper side of the end portion 14a of the duct 14 so as to cover the air outlet portion 14b.

  In addition, the extending portion 19b is provided with a step 19d on the lower side of the air outlet portion 14b.

  For example, using a water cutter or the like, a carpet main body 17a in which the carpet main body 17a covering the air outlet portion 14b shown in FIG. 10 and the resin layer 17b on the back surface are welded to the upper surface of the extending portion 19b shown in FIG. As shown in FIG. 11, a carpet opening 17c is formed in the interior of the carpet body 17a.

  For this reason, the periphery of this carpet opening part 17c is closely_contact | adhered to the upper surface of the duct 14 and the extension part 19b shown in FIG.

Further, as shown in FIG. 11, a step 19d of the extending portion 19b shown in FIG. 9 is provided below the formed air outlet portion 14b. The front end 22a is locked.
(Manufacturing method of molded carpet for vehicle of Example 1 and operation of this manufacturing method)
Next, based on FIG.12 and FIG.13, the manufacturing method of the molded carpet 11 for vehicles and the effect | action of this manufacturing method are demonstrated.

As shown in FIGS. 12 and 13, using a press device having a lower mold 23 of an upper surface shape corresponding to the shape of the floor panel 12 of the vehicle body shown in FIGS.
The cushion spacer 15 is disposed at a predetermined position on the upper surface of the lower mold 23, and the ducts 14 and 14 assembled by joining the lower member 19 and the upper member 27 in advance are respectively connected to the cushion spacers 15 and 15. It arrange | positions so that it may be latched by the side edge part upper surface 15b, 15b.

  As described above, the cushion spacer 15 is arranged in advance on the lower mold 23 and the duct 14 is arranged in parallel with the cushion spacer 15, so that it is possible to position the duct 14 without using a separate jig or the like. The duct 14 can be positioned at a desired position.

  Next, as shown in FIG. 12, the resin layer 17b of the thermoplastic resin provided on the back surface of the carpet body 17a is preheated and melted, and the carpet body 17a is placed between the lower mold 23 and the upper mold 24. The upper mold 24 corresponding to the lower mold 23 is moved down and pressed by the upper mold 24 and the lower mold 23 by being interposed and placed on the upper side of the lower mold 23 on which the duct 14 and the cushion spacer 15 are arranged. .

  For this reason, the carpet body 17a is formed in the floor panel 12 in a desired shape substantially along the shape, and the upper surface of the upper member 27 of the duct 14 and the cushion spacer are formed on the resin layer 17b on the back surface of the carpet body 17a. Fifteen upper surfaces 15a are welded to each other.

Thus, the molding process of the carpet body 17a and the joining process of the duct 14 and the cushion spacer 15 to the carpet body 17a are performed in one process.
The number of work processes is reduced, work efficiency is increased, and an increase in manufacturing cost is suppressed.

At this time, as shown in FIG. 12, the flanges 19a and 19a of the lower member 19 of the ducts 14 and 14 are respectively locked by the side edge upper surfaces 15b and 15b of the cushion spacer 15,
Gap 25, 25 is provided between the lower side of the lower member 19 of the duct 14 and the upper surface of the lower mold 23 of the press device,
The upper surface of the upper member 27 and the upper surface of the cushion spacer 15 are approximately flush with each other in the vertical direction, and the upper mold 24 and the lower mold 23 are pressure-molded to form the duct 14 and the cushion spacer 15. By welding to the surface of the resin layer 17b,
Since the carpet body 17a is pressed against the upper surface of the upper member 27 and the upper surface of the cushion spacer 15 with equal pressure, the upper surface of the upper member 27, the upper surface of the cushion spacer 15, and the carpet body. The back surface of 17a can be welded uniformly.

  In addition, since the gaps 25 are provided between the lower side of the lower members 19 and 19 and the lower die of the press device, both sides of the ducts 14 and 14 are applied during pressurization by the press device. The cushion spacers 15 and 15 are elastically deformed so that the lower members 19 and 19 of the ducts 14 and 14 do not come into contact with the lower mold of the press device. , 14 can be prevented from being deformed or broken.

  The upper member 27 and the lower member 19 used here are previously formed into a desired shape by press molding or the like.

  In this way, by dividing the duct 14 into the upper member 27 and the lower member 19 and molding the duct 14, the duct 14 can be molded individually by the upper member 27 and the lower member 19, respectively. It becomes possible to give the duct 14 a certain strength.

  Further, since the molding shape of the upper member 27 and the lower member 19 of the duct 14 is simpler than that of a conventional cylindrical duct, it is possible to perform molding such as press working. The degree of freedom of setting etc. increases.

  In addition, by dividing the duct 14 into the upper member 27 and the lower member 19 and molding the upper member 27 and the lower member 19, it becomes possible to perform the water cooling of the mold of the press device. Thus, the time for the molding process can be shortened.

  In addition, the plate thickness of the upper member 27 and the lower member 19 of the duct 14 can be selected from any material / thickness for each member as compared to blow molding, so that the upper member 27 and the lower member 19 of the duct 14 can be selected. The strength can be set to a desired strength.

  For this reason, the upper member 27 can be used as a reinforcing member for the floor of the passenger compartment.

Further, the strength of the duct 14 for preventing deformation or breakage of the duct 14 with respect to the pressure of heating and pressing when the carpet body 17a, the duct 14 and the cushion spacer 15 are integrally molded is set to a desired strength. Can be set to
(Operation of Molded Carpet for Vehicle of Example 1)
The operation of the first embodiment will be described.

As shown in FIGS. 1 and 2, the carpet body 17a is formed along the shape of the upper surface of the floor panel 12 of the vehicle body, and the duct 14 and the cushion spacer 15 are integrally formed on the back surface side of the carpet body 17a. To be joined to
When the carpet body 17a is laid on the floor panel 12, the duct 14 and the cushion spacer 15 can be arranged in a predetermined position.

  And since the duct 14 is arrange | positioned in the state supported by the cushion spacer 15 via the carpet main body 17a, this duct 14 can be arrange | positioned in the stable state.

Further, as shown in FIG. 3, since the height of the cushion spacer 15 is higher than the height of the duct 14, for example, when a force F is applied from above the position where the duct 14 is disposed,
Before the force is applied to the lower part of the duct 14, the elasticity of the cushion spacers 15 and 15 acts against this force F.

  The elastic forces f1 and f2 of the cushion spacers 15 and 15 act from below, the resistance against the force F is dispersed, the force f applied from below to the duct 14 is relaxed, and the duct 14 is deformed or damaged. It becomes difficult.

  As shown in FIGS. 3 to 8, the duct 14 and the back side of the carpet body 17a are welded, and there is no space between the duct 14 and the carpet body 17a. Can be suppressed.

  In addition, since the back surface side of the carpet body 17a is welded to the top surface of the duct 14, the surface of the carpet body 17a that is welded to the top surface of the duct 14 becomes uniform. No undulations on the surface.

Further, since the resin layer 17b of thermoplastic resin provided for molding the carpet body 17a is used to weld the duct 14 and the cushion spacer 15 to the back side of the carpet body 17a,
The forming agent for forming the carpet body 17a into a desired shape and the welding agent for the duct 14 and the cushion spacer 15 are shared, thereby reducing the number of members used for manufacturing and suppressing an increase in manufacturing cost. it can.

3 to 8, the duct 14 is divided into an upper member 27 and a lower member 19, and the lower member 19 is provided with flange portions 19a and 19a. In order to join the member 19 and the upper member 27 to form the duct 14,
Compared to a conventional cylindrical duct, the molding shape of the upper member 27 and the lower member 19 of the duct 14 is simplified, and molding such as press working becomes possible. Therefore, the material, strength, etc. of the duct 14 are set. The degree of freedom increases.

  Furthermore, the plate thickness of the upper member 27 and the lower member 19 of the duct 14 can be selected from any material / thickness for each member as compared to blow molding, so the strength of the upper member 27 and the lower member 19 of the duct 14 can be selected. Can be set to a desired intensity.

  Thus, since there is a degree of freedom in setting the strength, the upper member 27 can be used as a reinforcing member for the floor in the vehicle interior.

  Further, by forming the duct 14 having a predetermined surface rigidity on the upper member 27, the duct 14 is deformed with respect to the force applied from the upper side of the carpet body 17a at the position where the duct 14 is disposed. Or while being hard to break, the floor surface of this duct 14 vicinity can be reinforced.

Since the flange portions 19a and 19a of the lower member 19 are locked to the side edge portion upper surface 15b of the cushion spacer 15,
When a force is applied from above the carpet body 17a to the position where the duct 14 is disposed, the force applied to the upper surface of the duct 14 is cushioned to the cushion spacer 15 via the side edge upper surfaces 15b and 15b. The elasticity of the cushion spacer 15 transmitted to the spacer 15 also acts on the carpet body 17a at the position where the duct 14 is disposed.

  For this reason, this force is dispersed and the force applied to the duct 14 is relaxed, so that the duct 14 is hardly deformed or damaged.

Since the upper surface of the upper member 27 and the upper surface 15a of the cushion spacer 15 are substantially flush with each other in the vehicle vertical direction,
The uniformity of the upper surface of the carpet body 17a is maintained between the portion where the duct 14 is disposed and the portion where the duct 14 is not disposed, so that the surface of the carpet body 17a is not wavy and looks good.

  Further, since the joint portions 20a and 20a in FIG. 4 and the joint portions 20c and 20c in FIG. 8 are sandwiched between the side edge portion upper surfaces 15b and 15b of the cushion spacer 15 and the back surface of the carpet body 17a, The duct 14 is clamped in a stable state.

  Furthermore, air leakage from the joint portions 20a and 20a in FIG. 4 and the joint portions 20c and 20c in FIG. 8 can be reduced.

Further, as shown in FIG. 11, the periphery of the carpet opening 17c is in close contact with the end 14a of the duct 14 and the extending portion 19b of FIG.
When finishing by attaching a panel etc. to the blower outlet part 14b, attachment work becomes easy and the appearance of the finish is good.

Then, as shown in FIG. 11, a vehicle front of an option mat 22 for a vehicle is provided by a step 19 d provided on the lower member 19 below the air outlet 14 b formed at the end 14 a of the duct 14. Because the front end portion 22a of the
When the option mat 22 is laid in the vehicle compartment, the orientation of the option mat 22 is good.

  Further, as shown in FIGS. 1 to 8, since the spacer member 16 is disposed between the duct 14 and the floor panel 12, generation of noise due to contact between the duct 14 and the floor panel 12 is prevented. it can.

  Further, for this reason, even if a force is applied from above the position where the duct 14 is disposed, the duct 14 and the floor panel 12 are not in direct contact with each other, so that the duct 14 is hardly deformed or damaged.

  In addition, since a spacer member having heat insulation is interposed between the floor panel 12 made of metal or the like and the duct 14 having high heat conductivity, the heat insulation of the duct 14 is improved.

  Next, the manufacturing method of the molded carpet 11 for the vehicle according to the second embodiment of the present invention will be described with a focus on the parts different from the first embodiment, and the same or equivalent parts as the first embodiment will be denoted by the same reference numerals. explain.

  14 and 15 show a method for manufacturing the molded carpet 11 for the vehicle according to the second embodiment.

(Method for producing molded carpet for vehicle of Example 2)
As shown in FIGS. 14 and 15, using a press device having a lower mold 23 having an upper surface shape corresponding to the shape of the floor panel 12 of the vehicle body shown in FIGS.
The cushion spacer 15 is disposed at a predetermined position on the upper surface of the lower mold 23, and the upper member 27 is disposed so as to be locked by the side edge portion upper surfaces 15 b and 15 b of the cushion spacer 15 and 15.

  In this way, the cushion spacer 15 is previously arranged on the lower mold 23 and the upper member 27 is arranged in parallel with the cushion spacer 15, so that there is no need to use a separate jig or the like for positioning the duct 14. The upper member 27 can be positioned at a desired position.

  Next, a thermoplastic resin layer 17b provided on the back surface of the carpet body 17a is heated and melted in advance, and the carpet body 17a is interposed between the lower mold 23 and the upper mold 24, and the upper member 27 and The upper die 24 is placed on the upper side of the lower die 23 on which the cushion spacer 15 is disposed, and the upper die 24 corresponding to the lower die 23 is lowered and pressed by the upper die 24 and the lower die 23.

  For this reason, the carpet body 17a is formed on the floor panel 12 in a desired shape substantially along the shape, and the upper member 27 and the upper surface 15a of the cushion spacer 15 are formed on the resin layer 17b on the back surface of the carpet body 17a. Are welded to each other.

Thus, the molding process of the carpet body 17a and the joining process of the flat plate member 18 and the cushion spacer 15 to the carpet body 17a are performed in one process.
The number of work processes is reduced, work efficiency is increased, and an increase in manufacturing cost is suppressed.

At this time, as shown in FIG. 14, both side ends of the upper member 27 are locked by the side edge upper surfaces 15b and 15b of the cushion spacer 15,
The upper die 24 and the lower die 23 are pressure-molded so that the upper surface of the upper member 27 and the upper surface of the cushion spacer 15 are substantially flush with each other in the vertical direction, and the duct 14 and the cushion spacer 15 are made to be a resin layer. By welding to the surface of 17b,
Since the carpet body 17a is pressed against the upper surface of the upper member 27 and the upper surface of the cushion spacer 15 with equal pressure, the upper surface of the upper member 27, the upper surface of the cushion spacer 15, and the carpet body. 17a can be welded uniformly.

  Further, after the upper member 27 and the cushion spacer 15 are welded to the resin layer 17b on the back surface of the carpet body 17a, the lower member 19 is joined to the lower surface of the flat plate member 18 as shown in FIG.

  As described above, the molding process of the carpet body 17a and the joining process of the upper member 27 and the cushion spacer 15 to the carpet body 17a are performed in one process, and then joined to the back surface of the carpet body 17a by another process. The lower member 19 is joined to the upper member 27.

  For this reason, the freedom degree of the setting of the material of this upper side member 27 and the lower side member 19 increases.

  Therefore, for example, the upper member 27 and the lower member 19 may be made of different materials, and a member made of a material that can simplify the manufacturing process, reduce costs, and the like can be used.

  Next, regarding the molded carpet for a vehicle according to the third embodiment of the present invention, the configuration of the molded carpet for a vehicle will be described with reference to FIGS.

  Here, the description will focus on parts different from the first and second embodiments, and the same or equivalent parts as in the first and second embodiments will be described with the same reference numerals.

(Configuration of molded carpet for vehicle of Example 3)
5 and 6 show the AA cross section of FIG. 1 in the third embodiment.

  As shown in FIGS. 5 and 6, the duct 14 disposed in the flat portions 13 c and 13 c of the floor tunnel portion 13 shown in FIGS. 1 and 2 is formed of a hat-like member 26 having a predetermined surface rigidity. The flange portions 26b and 26b and the flange portions 19a and 19a of the lower member 19 having a substantially reverse hat shape in cross section are joined in advance.

The joint portions 20b and 20b of the duct 14 in which the flange portions 26b and 26b and the flange portions 19a and 19a are joined, and the flange portions 26b and 26b of the hat-like member 26 are adjacent to both sides of the duct 14 in parallel. The upper surface 26a of the hat-shaped member 26 of the duct 14 and the upper surfaces 15a and 15a of the cushion spacers 15 and 15 in a state where the cushion spacers 15 and 15 are locked by the side edge upper surfaces 15b and 15b of the cushion spacers 15 and 15, respectively. Are welded to the resin layer 17b on the back side of the carpet body 17a at substantially the same height.
(Operation of the molded carpet for vehicle of Example 3)
The operation of the third embodiment will be described.

  As shown in FIGS. 5 and 6, by forming a duct 14 having a predetermined surface rigidity on the hat-like member 26, it is applied from the upper side of the carpet body 17a at the position where the duct 14 is disposed. The duct 14 can be hardly deformed or broken against a force, and the floor near the duct 14 can be reinforced.

And because the joint portions 20b, 20b are locked to the side edge portion upper surfaces 15b, 15b of the cushion spacers 15, 15,
When a force is applied from above the carpet body 17a to the position where the duct 14 is disposed, the force applied to the upper surface of the duct 14 is cushioned to the cushion spacer 15 via the side edge upper surfaces 15b and 15b. The elasticity of the cushion spacer 15 transmitted to the spacer 15 also acts on the carpet body 17a at the position where the duct 14 is disposed.

  For this reason, this force is dispersed, the force applied to the duct 14 is relaxed, and the duct 14 is hardly deformed or damaged.

Since the upper surface 26b of the hat-shaped member 26 and the upper surfaces 15a and 15a of the cushion spacer 15 are substantially flush with each other in the vehicle vertical direction,
The uniformity of the upper surface of the carpet body 17a is maintained between the portion where the duct 14 is disposed and the portion where the duct 14 is not disposed, so that the surface of the carpet body 17a is not wavy and looks good.

  Other configurations and functions and effects are substantially the same as those in the first embodiment, and thus description thereof is omitted.

  Although the best embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design changes that do not depart from the gist of the present invention are possible. Are included in the present invention.

  In the molded carpet 11 for vehicle according to the first embodiment, the duct 14 and the cushion spacer 15 are welded to the back surface side of the carpet body 17a. However, any joining method may be used. For example, adhesion by an adhesive may be used.

  Moreover, in the molded carpet 11 for a vehicle of Example 1, the spacer member 16 is arrange | positioned between the floor panel 12 and the duct 14, However, This spacer member 16 does not necessarily need to be arrange | positioned.

  When this spacer member 16 is provided, the molded carpet 11 for a vehicle may be pasted from the back side to the back side of the duct 14 after manufacturing, or may be previously laid on the floor panel 12 of the vehicle body. .

  And in this Example 1 or Example 3, although the upper member of the duct 14 is flat form or a cross section is on a substantially reverse hat, if the duct is joined to the back surface of the carpet main body 17a, the shape of the duct will be described. Can have any shape. It is not always necessary to have a flange portion.

  For example, the cross section of the duct may be a square shape.

1 is a cross-sectional perspective view of a floor panel of a vehicle body for explaining a molded carpet for a vehicle according to a first embodiment of the present invention and a portion of the molded carpet for a vehicle laid on the floor panel. FIG. 2 is an exploded perspective view in which a duct and a carpet body are disassembled and drawn in the vehicle vertical direction of FIG. 1 for explaining a molded carpet for a vehicle according to Example 1 of the best mode of the present invention. It is AA sectional drawing of FIG. 1 explaining the molded carpet for vehicles of Example 1 of the best mode of this invention. FIG. 4 is an exploded view in the vertical direction of FIG. 3 for explaining a molded carpet for a vehicle according to Example 1 of the best mode of the present invention. It is AA sectional drawing of FIG. 1 explaining the molded carpet for vehicles of Example 3 of this invention in the best form, and is a figure at the time of using the duct which has a substantially hat-shaped upper member. FIG. 6 is an exploded view in the vertical direction of the AA cross-sectional view of FIG. 5 for explaining a molded carpet for a vehicle according to Example 3 of the best mode of the present invention. It is BB sectional drawing of FIG. 1 explaining the molded carpet for vehicles of Example 1 of the best form of this invention. FIG. 8 is an exploded view in the vertical direction of FIG. 7 for explaining a molded carpet for a vehicle according to Example 1 of the best mode of the present invention. FIG. 2 is an exploded cross-sectional view in the vertical direction of the CC cross-sectional view of FIG. 1 for explaining the molded carpet for a vehicle according to the first embodiment of the present invention. It is CC sectional drawing of FIG. 1 explaining the molded carpet for vehicles of Example 1 of this invention best mode, and is sectional drawing before carpet opening part formation. In addition, the dashed-two dotted line of a figure has shown a part of cut surface of an opening part. It is CC sectional drawing of FIG. 1 explaining the molded carpet for vehicles of Example 1 of this invention best mode, and is a figure in case the option mat is laid. A method for manufacturing a molded carpet for a vehicle according to Example 1 of the best mode of the present invention, a lower die of a press device, a cushion spacer arranged at a predetermined position of the lower die of the press device, and the cushion spacer FIG. 3 is a cross-sectional view of a duct that is locked by the upper die and an upper die corresponding to the lower die, and is a view before pressurization by a press device. A method for manufacturing a molded carpet for a vehicle according to Example 1 of the best mode of the present invention, a lower die of a press device, a cushion spacer disposed at a predetermined position of the lower die of the press device, and the cushion spacer It is sectional drawing of the duct arrange | positioned latched by and the upper mold | type corresponding to a lower mold | type, It is a figure in the pressurization by a press apparatus. The lower mold of the press device, the cushion spacer arranged at a predetermined position of the lower die of the press device, and the cushion spacer for explaining the manufacturing method of the molded carpet for the vehicle according to the second embodiment of the best mode of the present invention It is sectional drawing of the upper member of the duct arrange | positioned latched by and the upper mold | type corresponding to a lower mold | type, It is a figure under the pressurization by a press apparatus. It is sectional drawing before joining the upper member and lower member explaining the manufacturing method of the molded carpet for vehicles of Example 2 of this invention in the best mode. It is sectional drawing explaining the carpet for motor vehicles of one prior art example, and is sectional drawing of this car carpet and the floor panel of the vehicle body by which this motor vehicle carpet is laid. A lower mold of a press apparatus, a molded felt laid on the lower mold of the press apparatus, a heater duct disposed on the molded felt, and a molded carpet before molding, illustrating a method of manufacturing a conventional automobile carpet FIG. 4 is a cross-sectional view of the upper die corresponding to the lower die, and is a view before pressurization by the press device.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 Molded carpet 12 for vehicles Floor panel 14 Duct 14a End part 14b Outlet part 15 Cushion spacer 15a Upper surface 15b Side edge upper surface 16 Spacer member 17a Carpet body 17b Resin layer 17c Carpet opening 18 Flat plate member 18a Side end 18b Upper surface 19 Lower member 19a Flange portion 19d Step 21 Reinforcing member 21a Joint surface 21b Upper surface 21c Side portion 22 Optional mat 22a Front end portion 23 Lower die 24 Upper die 25 Gap 26 Hat-like member 26a Upper surface 26b Flange portion 27 Upper member

Claims (14)

A molded carpet for a vehicle having a carpet body formed on the floor panel of the vehicle body along the shape of the upper surface of the floor panel and having a carpet body interposed between the floor panel and a duct and a cushion spacer. Because
The carpet is bonded to the back surface side of the carpet body in advance, and the cushion spacer having a height higher than the height of the duct is integrally bonded to the remaining portion where the duct is not bonded. When the vehicle is laid, the duct and the cushion spacer are arranged side by side on the floor panel.   The molded carpet for a vehicle according to claim 1, wherein a resin layer of a thermoplastic resin to which the duct and the cushion spacer are welded by heat and pressure molding is formed on a back surface side of the carpet body.   The duct is divided into an upper member and a lower member, and at least the lower member has a flange portion joined to the upper member formed on a side edge portion in an outward direction. The molded carpet for vehicles according to claim 1 or 2.   A flange portion of the upper member or a part of the back surface side of the upper member is joined to a flange portion of the lower member, and the upper member has a predetermined surface rigidity. The molded carpet for vehicles according to claim 3.   The molded carpet for vehicles according to any one of claims 1 to 4, wherein a flange portion of the lower member is locked to an upper surface of a side edge portion of the cushion spacer.   The molded carpet for a vehicle according to any one of claims 3 to 5, wherein an upper surface of the upper member and an upper surface of the cushion spacer are substantially flush with each other in a vehicle vertical direction.   The flange portion of the lower member and the upper member joined to the flange portion are sandwiched between the upper surface of the side edge portion of the cushion spacer and the back surface of the carpet body. The molded carpet for vehicles according to any one of 1 to 6.   A carpet opening that exposes the air outlet formed at the end of the duct to the space in the vehicle interior is formed on the interior side of the carpet body, and the periphery of the carpet opening is 8. The molded carpet for a vehicle according to claim 1, wherein the carpet is in close contact with the duct.   The front end portion of the vehicle option mat in front of the vehicle is locked by a step provided on the lower member below the air outlet portion formed at the end portion of the duct. Item 10. The molded carpet for vehicle according to Item 8.   The molded carpet for vehicles according to any one of claims 1 to 9, wherein a spacer member is disposed between the duct and the floor panel. A step of disposing the cushion spacer and the duct at a predetermined position of a lower mold corresponding to the floor panel; a step of disposing the heated carpet body on the upper side of the lower mold;
The upper mold corresponding to the lower mold and the lower mold are pressurized, and the duct and the cushion spacer are joined to the back side of the carpet body, and the carpet body follows the shape of the floor panel. The method for producing a molded carpet for a vehicle according to claim 1, further comprising a step of forming into a shape.   The flange part joined to the lower member of the duct is locked by the cushion spacer, and a gap is provided between the lower side of the lower member and the lower die of the press device, The upper surface of the upper member and the upper surface of the cushion spacer are welded to the surface of the resin layer so that the upper surface of the member and the upper surface of the cushion spacer are substantially flush with each other in the vertical direction. The method for producing a molded carpet for a vehicle according to claim 11, wherein the pressure by heat and pressure molding is applied substantially uniformly.   By dividing the duct into the upper member and the lower member and forming the duct, the duct can be formed separately by the upper member and the lower member, so that the duct has a certain strength. The method for producing a molded carpet for a vehicle according to claim 11 or 12, characterized in that: The duct is divided into the upper member and the lower member, and the cushion spacer and the upper member are arranged at a predetermined position of the lower die corresponding to the floor panel, and above the lower die. Placing the heated carpet body;
The upper mold corresponding to the lower mold and the lower mold are pressed to join the upper body member and the cushion spacer to the carpet body, and the carpet body is shaped according to the shape of the floor panel. Molding process;
The method for producing a molded carpet for a vehicle according to claim 11, further comprising a step of joining the lower member to the upper member joined to the back surface side of the carpet body.

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