JP4844017B2 - Mat material - Google Patents

Description

The present invention relates to a mat member provided with a surface layer of fibrous the surface.

  In the mat material laid in the interior of an automobile or the like, the peripheral portion may be processed in order to protect the peripheral portion including the cut surface (see, for example, Patent Document 1). In this peripheral edge processing, the raised pile of the mat material terminal portion is cut away leaving the backing material, and the peripheral edge of the mat material is covered with tape, molding or the like and is sewn from above.

In such a conventional mat material, the processed mat material peripheral edge exists in a frame shape in a state of being installed indoors, and the appearance different from the central portion stands out, so that the indoor floor on which the mat material is installed It appears as a boundary between the surface. For this reason, the design of the mat material is impaired, for example, the sense of unity in design is impaired. Further, the frame-shaped peripheral edge portion of the mat member has a different tactile sensation from the central portion, which may cause the user to feel uncomfortable.
Japanese Patent Laid-Open No. 9-238816

In view of the above facts, an object of the present invention is to provide a mat member that protects the peripheral edge part and provides the peripheral part with integrity with the central part.

The mat material of the present invention described in claim 1 is composed of a base material, and a large number of fibrous piles that are supported by the base material and are erected with respect to the base material, and the pile is flexible. and covering cormorant Table cortex to the distal portion of the surface of the substrate provided with the sex, the substrate-side portion of the side surface portions of the skin layer, integrally covering the back side end portion of the side and the base material of the substrate A covering portion to be pressed, and holding and pressing the base material side portion of the skin layer covered by the covering portion in the direction from the front surface to the back surface of the base material, the skin layer of the pile The restoring force of the pile densely inside the side surface portion is applied, and the side surface portion of the skin layer is bent and warped so as to cover the upper side of the covering portion at the upper portion on the side surface portion side of the skin layer. has an end portion protecting means, wherein the end protection means, the front and back of the substrate through said substrate A sewing thread that connects both ends of the covering portion by sewing, and both ends of the covering portion that are connected by sewing sandwich the base material side portion of the skin layer and the base material, and the sewing The yarn is positioned away from the side of the base as it goes from the front side to the back side of the base .

  Here, the direction from the surface of the base material to the back surface includes both the thickness direction from the surface of the base material to the back surface and the oblique direction from the surface of the base material to the back surface.

According to the mat material of the present invention described in claim 1, the skin layer composed of a large number of fibrous piles erected with respect to the substrate is supported by the substrate and the pile is flexible. The end protection means covers the surface of the base material up to the end, and the covering portion is integrated with the base material side portion, the base material side portion and the back surface end portion of the base material in the side surface portion of the skin layer. The base material side portion of the skin layer covered with the covering portion is pressed and held in the direction from the front surface to the back surface of the base material. Thus, the peripheral part of the mat material is protected by covering the side part or the like of the base material with the covering part, and the base part side part of the skin layer is directed from the surface of the base material to the back surface by the covering part. By pressing and holding in the direction, the restoring force of the pile densely inside the side surface part of the skin layer of the pile acts so that the upper part of the side surface side of the skin layer covers the upper side of the covering part The side surface portion of the skin layer is bent and warped. For this reason, it is difficult to see the end protection means including the covering portion, and the periphery of the mat member can be integrated with the central portion of the mat member.

Further, since the end protection means is configured such that both ends of the covering portion on the front and back sides of the base material are connected by sewing so as to sandwich the base material side portion of the skin layer and the base material, so that the skin is configured with a simple configuration. The base material side portion in the side surface portion of the layer can be pressed and held in the direction from the front surface to the back surface of the base material.

Furthermore, the end protection means presses and holds the base material side portion of the side surface portion of the skin layer in the direction from the front surface to the back surface of the skin layer by sewing with the sewing thread. Here, since the sewn sewing thread is located away from the side of the base material as it goes from the front surface side to the back surface side of the base material, even if the seam allowance on the skin layer side is reduced, the covering portion is covered by the sewing thread. Is securely held.

  As described above, according to the mat member of the present invention, there is an excellent effect that the peripheral portion can be integrated with the central portion while protecting the peripheral portion.

  A first embodiment of a mat member according to the present invention will be described with reference to the drawings. The mat material in the present embodiment is a floor mat as an interior material laid in the interior of a car.

  As shown in FIG. 1A, the floor mat 10 includes a mat substrate 12 having a back surface 212 as a laying surface. The mat base material 12 has a laminated structure, and includes a base fabric 14 made of felt in a lower layer. The base fabric 14 provides cushioning properties. A backing layer 16 is provided on the base fabric 14 so as to cover the base fabric 14.

  Above the backing layer 16 is a skin layer 18 supported by the backing layer 16. The skin layer 18 is composed of a large number of fibrous piles 19 that are implanted in the backing layer 16 at the base end and are erected in parallel to each other. A surface that is sometimes directed upward) up to the end 16A. The tips of the piles 19 of the skin layer 18 are in a dense state, and give the floor mat 10 a volume feeling.

  As shown in FIG. 1B and FIG. 2, a peripheral edge protection portion 20 as an edge protection means is disposed on the side portion of the floor mat 10. The peripheral protection part 20 includes a decorative yarn 22 as a covering part, a base material side part 118A in a side part 118 as a side part of the skin layer 18, a side part 12A as a side part of the mat base material 12, and a mat. The back surface end portion 12B of the base material 12 is continuously and integrally covered so as to be wrapped with a decorative yarn 22 having a substantially U-shaped cross section. The decorative yarns 22 are closely arranged as shown in FIG.

  Here, the covering width L (see FIG. 2) in which the base material side portion 118A of the side surface portion 118 of the skin layer 18 is covered with the decorative yarn 22 is compared with the thickness T of the mat base material 12 in this embodiment. small.

  Both end portions 22A and 22B of the decorative yarn 22 on the front and back sides of the mat base material 12 are joined by a locking thread 24 that forms a part of the peripheral protection portion 20 by sewing, and the base portion 118A of the skin layer 18 and the mat The substrate 12 is sandwiched. In this way, the peripheral edge protection unit 20 presses the base material side portion 118A of the skin layer 18 covered with the decorative yarn 22 in an oblique inward direction (arrow A direction) from the front surface 112 of the mat base material 12 toward the back surface 212. And hold (restraint).

  As shown in FIG. 1A, the sewing needle 26 sewn with the locking thread 24 operates so as to pass through the upper end 22A of the decorative thread 22 and the lower end 22B of the decorative thread 22, and is shown in FIG. As a result, the entire circumference is sewn. As shown in FIGS. 1B and 2, the sewn portion 24 </ b> A of the locking thread 24 at the upper end 22 </ b> A of the decorative thread 22 is the sewn portion 24 </ b> B of the locking thread 24 at the lower end 22 </ b> B of the decorative thread 22. Compared to the side of the floor mat 10, the position is closer to the side (outside position).

  The base material side portion 118A of the side surface portion 118 of the skin layer 18 is inclined inward by the decorative yarn 22 and the locking yarn 24, and the side surface portion 118 of the skin layer 18 is bent and warped. When overlock processing is performed, a lower thread is required in addition to the decorative thread 22 and the locking thread 24, although not shown in FIGS.

  Next, the operation of the first embodiment will be described.

  As shown in FIG. 1A, the fibrous skin layer 18 that covers the surface 112 of the mat base material 12 to the end portion 16 </ b> A is supported by the mat base material 12. As shown in FIG. 1 (B), the peripheral edge protection portion 20 is configured such that the decorative yarn 22 has a base material side portion 118 </ b> A in the side surface portion 118 of the skin layer 18, a side surface portion 12 </ b> A of the mat base material 12 and The end portion 12B is integrally covered, and the base material side portion 118A of the skin layer 18 covered with the decorative yarn 22 is sewn from the front surface 112 of the mat base material 12 to the back surface 212 by sewing with the locking thread 24. It is pressed and held (restrained) in a diagonally inward direction (arrow A direction).

  In this way, by covering the side surface portion 12A and the like of the mat base material 12 with the decorative yarn 22, the peripheral edge portion of the floor mat 10 is protected and yarn fraying from the side surface portion 12A of the mat base material 12 is prevented. . Further, the base material side portion 118A in the side surface portion 118 of the skin layer 18 is pressed and held in an oblique inward direction (arrow A direction) from the front surface 112 of the mat base material 12 to the back surface 212, whereby the base material side portion 118A. Is restrained inward, but the upper part is in an unconstrained state, and the restoring force of the pile 19 densely inside the side surface part 118 acts, so that the upper part of the skin layer 18 spreads outward and protects the periphery. The upper part of the part 20 is covered. Thereby, when it sees from the upper direction (arrow Z direction), the peripheral protection part 20 becomes difficult to see, and the peripheral part of the floor mat 10 can have the integrity with the center part of the floor mat 10. As a result, the merchantability of the floor mat 10 can be improved.

  In addition, even when the floor mat 10 is abutted against a design surface (for example, carpet or garnish) that forms a surrounding flat surface or a vertical wall of the floor mat 10, the boundary becomes inconspicuous and an expression with a sense of unity with the surroundings is obtained. It becomes possible to improve the sense of integration.

  Here, in the peripheral protection part 20, both end portions 22A and 22B of the decorative thread 22 on the front and back sides of the mat base material 12 are connected by a locking thread 24 that constitutes a part of the peripheral protection part 20 by sewing, and an outer skin layer. 18 is sandwiched between the base material side portion 118A and the mat base material 12, so that the base material side portion 118A in the side surface portion 118 of the skin layer 18 is changed from the front surface 112 of the mat base material 12 to the back surface 212 with a simple configuration. It can be pressed and held in the diagonally inward direction (arrow A direction).

  Further, as shown in FIG. 1B, the sewing portion 24A in the upper end portion 22A of the decorative yarn 22 is slanted inwardly from the front surface 112 of the mat base material 12 toward the back surface 212 by sewing with the locking thread 24. Slightly pulled in the direction (arrow A direction), slightly warped in the pulling direction, and the sewn portion 24B at the lower end 22B of the decorative thread 22 is pulled slightly upward (in the direction of arrow B). . For this reason, a slight warp that is convex upward occurs in the portion of the mat base 12 near the surface end portion 16A. The pile 19 supported by a portion slightly inclined outward on the end side from the center line CL of the warp has its lower end root portion slightly directed outward, and the upper portion of the pile 19 is easily directed outward. .

Next, a second embodiment of the mat material will be described with reference to FIG. The second embodiment is an embodiment of the present invention, in which the covering portion is a tape material 28. Since other configurations are substantially the same as those in the first embodiment, the same reference numerals are given and description thereof is omitted.

  As shown in FIG. 3, a tape material 28 is disposed as a covering portion, and the tape material 28 includes a base material side portion 118 </ b> A in the side surface portion 118 of the skin layer 18, a side surface portion 12 </ b> A of the mat base material 12, and a mat base. The length is such that the back end 12B of the material 12 can be wrapped and covered.

  This tape material 28 uses a tape guide (not shown) to form a base material side portion 118A in the side surface portion 118 of the skin layer 18, a side surface portion 12A of the mat base material 12, and a back surface end portion 12B of the mat base material 12 all around the periphery. It is folded to wrap around the circumference. Both end portions 28A and 28B of the tape material 28 are connected by a sewing thread 24 constituting a part of the peripheral protection portion 20 by sewing, and sandwich the base material side portion 118A of the skin layer 18 and the mat base material 12.

  As the tape material 28, a tape material made of a soft plastic film, a tape material in which a thin cloth is laminated on a soft plastic film, a fibrous tape material, or the like can be applied.

Next, a third embodiment of the mat material will be described with reference to FIG. The third embodiment is an embodiment of the present invention, in which the covering portion is a molding 30. Since other configurations are substantially the same as those in the first embodiment, the same reference numerals are given and description thereof is omitted.

  As shown in FIG. 4, the molding 30 is arranged as a covering portion. The molding 30 is made of a U-shaped soft plastic in a sectional view formed by extrusion molding or the like, and using a molding guide (not shown), the base material side portion 118A in the side surface portion 118 of the skin layer 18 and the mat base material 12 are formed. The side surface portion 12A and the back surface end portion 12B of the mat base material 12 are covered. Both end portions 30A and 30B of the molding 30 are connected by a sewing thread 24 constituting a part of the peripheral protection portion 20 by sewing, and sandwich the base material side portion 118A of the skin layer 18 and the mat base material 12.

In the present embodiment, as in the first and second embodiments, sewing is performed obliquely with respect to the thickness direction of the mat base 12 , but as a reference example, the thickness direction of the mat base 12 You may sew in (the arrow Y direction and the opposite direction). Further, as another reference example, the opposing end portions of the opening of the molding may be pressed and plastically deformed and attached without sewing. As another reference example , the molding may be bonded to the mat base 12 with an adhesive without performing sewing, or welding may be performed using an ultrasonic welder.

Next, a fourth embodiment of the mat material will be described with reference to FIG. Note that the fourth embodiment is not an embodiment of the present invention but a reference example. In the fourth embodiment, the covering portion 32 is made of a thermoplastic resin. The peripheral edge protection portion 20 is in a state where the covering portion 32 presses the base material side portion 118A of the side surface portion 118 of the skin layer 18 in an oblique inward direction (arrow A direction) from the front surface 112 of the mat base material 12 toward the back surface 212. Immediately after the molten resin is extruded from the die having a U-shaped cross section, the side surface portion 12A of the mat base material 12 is cured with cooling after being welded around the side surface portion 12A. The side surface portion 12A of the mat base material 12 and the back surface end portion 12B of the mat base material 12 can be covered and retained. Since other configurations are substantially the same as those in the first embodiment, the same reference numerals are given and description thereof is omitted.

  As shown in FIG. 5, the covering portion 32 includes a base material side portion 118 </ b> A in the side surface portion 118 of the skin layer 18, a side surface portion 12 </ b> A of the mat base material 12, and a back surface end portion 12 </ b> B of the mat base material 12. The entire periphery is integrally covered. The peripheral protection portion 20 has a shape capable of restraining the base material side portion 118A and the like in the side surface portion 118 of the skin layer 18 by the coating portion 32 being cured by cooling after heating and melting, and the skin layer covered by the coating portion 32 The 18 base material side portions 118A are held (restrained) in a state where they are pressed in an oblique inward direction (arrow A direction) from the front surface 112 of the mat base material 12 to the back surface 212. Moreover, the base material side portion 118 </ b> A of the skin layer 18 covered with the coating portion 32 is also cured by the coating portion 32 being cured by cooling after being heated and melted.

  As a result, the base material side portion 118A is constrained inward, but the upper portion is in an unconstrained state, and the restoring force of the pile 19 that is densely inside the side surface portion 118 acts. The upper part spreads outside and covers the vicinity of the upper part of the peripheral protection part 20.

  In the above embodiment, the direction of pressing the base material side portion 118A in the side surface portion 118 of the skin layer 18 is illustrated in the direction of the arrow A, but the base material side portion of the skin layer covered by the covering portion is illustrated. The direction in which the peripheral protection part (end protection means) presses is not limited to this, and may be a direction from the surface of the base material toward the back surface. That is, the direction of pressing the base material side portion of the skin layer covered with the covering portion is the side surface side along the front surface 112 of the mat base material 12 from the thickness direction Y from the front surface 112 of the mat base material 12 to the back surface 212. Any direction may be used as long as the direction excluding the direction X from the side surface toward the inner side along the surface 112 of the mat base material 12 in the range from the direction X toward the inner side.

Next, a fifth embodiment of the mat material sewn by the mat material sewing apparatus will be described with reference to FIGS. The fifth embodiment is an embodiment of the present invention. The same members as those in the first to fourth embodiments are denoted by the same reference numerals, and the description thereof is omitted.

  The sewing device 40 (hereinafter simply referred to as “sewing device 40”) of the floor mat 10 shown in FIG. 6 covers the surface 112 (see FIG. 8) of the mat base 12 with the fibrous skin layer 18 to the end. Used for sewing the floor mat 10.

  As shown in FIG. 7, the sewing apparatus 40 includes a needle plate 45, and a sewing port 45 </ b> A is formed through the needle plate 45 so as to pass the sewing needle 62. A feed dog opening 45B is formed in a position close to the sewing opening 45A (left side in FIG. 7), and a mat feed dog 52 is disposed in the feed dog opening 45B so as to be driven. ing. A pressing member 54 is disposed above the feed dog 52. The pressing member 54 is urged downward by an upper coil spring (not shown), and presses the floor mat 10 (see FIG. 6) against the needle plate 45 during sewing. The floor mat 10 (see FIG. 6) is conveyed in the mat feeding direction (arrow S direction) by pressing by the pressing member 54 and driving of the feed dog 52.

  An abutting ruler 42 as a positioning means is fixed to the bed 44 by a screw 46 at a position close to the needle plate 45. As shown in FIG. 6, the abutting ruler 42 includes a protruding portion 43 that protrudes toward the arrangement side of the floor mat 10, and an end surface of the protruding portion 43 is applied to the side surface portion 12 </ b> A of the mat base material 12 and the sewing progress direction. The mat substrate 12 is positioned with respect to a direction perpendicular to the direction opposite to the arrow S direction. That is, the end face of the protruding portion 43 is applied to the side surface portion 12 </ b> A of the mat base material 12, so that the sewing width is kept constant.

  A pressing plate 48 as a pile guide is fixed to the upper surface portion of the abutting ruler 42 with screws 47. The pressing plate 48 is a thin plate and protrudes to the side where the floor mat 10 is arranged, and is curved into a long sickle shape on the side where the floor mat 10 is arranged, and extends downstream in the mat feeding direction (arrow S direction). .

  As shown in FIG. 7, the tip side portion 48A of the presser plate 48 is above the sewing opening 45A and slightly inward of the floor mat 10 (see FIG. 6) rather than the mat feeding direction (arrow S direction). It extends toward the direction toward. As shown in FIG. 6, the front end side portion 48A of the pressing plate 48 is configured to press the intermediate portion in the height direction of the pile 19 by rebound resilience above the sewing position. Inclining means is provided for inclining the intermediate portion in the height direction of the skin layer 18 (pile 19) at the end inward.

  An air nozzle 50A of the air supply device 50 is disposed above the abutting ruler 42 and the pressing plate 48, and the air nozzle 50A is connected in communication with an air source (not shown). The front end side of the air nozzle 50 </ b> A is an air outlet 50 </ b> B directed to the side surface 118 of the skin layer 18 in the floor mat 10.

  The air supply device 50 is configured to blow air from the air outlet 50B in a direction substantially perpendicular to the mat feeding direction (arrow S direction) during sewing, whereby the skin layer at the end of the floor mat 10 18 (pile 19) is arranged so that the direction of napping is aligned immediately before contacting the front end portion 48A of the pressing plate 48.

  A sewing needle 62 as a sewing needle for constituting a part of a sewing mechanism 60 as a sewing means is disposed above the sewing opening 45A of the needle plate 45 shown in FIG. As shown in FIG. 8, the sewing needle 62 is attached to the needle support 63 at the lower end of the needle bar 64. The needle bar 64 is connected to a drive motor 68 via a needle bar crank mechanism 66, and is driven up and down via the needle bar crank mechanism 66 by the drive of the drive motor 68.

  The sewing mechanism 60 moves the sewing needle 62 along a trajectory that is located away from the side surface portion 12A of the mat base material 12 toward the back surface 212 side of the mat base material 12 with respect to the end portion of the floor mat 10. It is designed to reciprocate and sew.

  In addition to the sewing needle 62, the sewing mechanism 60 of the present embodiment includes an upper and lower looper (not shown) that swings in conjunction with the operation of the sewing needle 62, and includes a sewing thread 70 passed through the sewing needle 62, and Overlock stitching (edge stitching) can be applied to the peripheral portion of the floor mat 10 by the upper and lower looper yarns 71 and 72 passed through the upper and lower loopers.

  In addition, in order to implement | achieve stable sewing, it is preferable to set the approach angle N of the sewing needle 62 with respect to the surface 112 of the mat | matte base material 12 into which the sewing needle 62 approachs to 20 degrees <= N <= 80 degrees. In the present embodiment, N = 65 ° is set as an optimum value in consideration of the range of swing motion of the upper and lower loopers (not shown) linked to the operation of the sewing needle 62.

  By such sewing, as shown in FIG. 8, the upper and lower looper threads 71 and 72 as the covering portions are made of the base material side portion 118A in the side surface portion 118 of the skin layer 18, the side surface portion 12A of the mat base material 12, and the mat. The back surface end portion 12 </ b> B of the base material 12 is covered. Further, the sewing thread 70 is sewn so as to be located away from the side surface portion 12A of the mat base material 12 as it passes through the mat base material 12 and moves from the front surface 112 side to the back surface 212 side. The upper and lower looper yarns 71 and 72 as covering portions on both sides of the mat base material 12 (the front end portion 71A of the mat base material 12 in the upper looper yarn 71 and the mat base material 12 in the lower looper yarn 72) The back end 72A) is connected.

  Next, the sewing method and operation of the floor mat 10 using the sewing device 40 of the fifth embodiment will be described.

  At the time of sewing, the pressing member 54 shown in FIG. 7 presses the floor mat 10 (see FIG. 6) against the needle plate 45, and the feed dog 52 is driven. As shown in FIG. The needle 62 is moved relative to the mat feeding direction (arrow S direction) which is the opposite direction of the sewing progress direction.

  At this time, the side surface portion 12A of the mat base 12 is directed in a direction perpendicular to the sewing progressing direction (the direction opposite to the arrow S direction) prior to the overlock sewing, and is applied to the end surface of the protrusion 43 of the abutting ruler 42. Thus, the mat substrate 12 is positioned in a direction perpendicular to the sewing progress direction (the direction opposite to the arrow S direction) (positioning step).

  Here, air is blown toward the pile 19 in the side surface portion 118 of the skin layer 18 of the floor mat 10 from the air outlet 50B in a direction substantially orthogonal to the mat feeding direction (arrow S direction). The direction of the napping of the pile 19 on the 18 side portions 118 is aligned.

  Next, the tip side portion 48A of the presser plate 48 presses the intermediate portion in the height direction of the pile 19 to which air is blown to incline inward, and as shown in FIG. The sewing needle 62 is reciprocated and sewn on a trajectory that is located away from the side surface portion 12A of the mat base material 12 toward the end portion of the mat base material 12 from the front surface 112 side to the back surface 212 side. Overlock stitching (edge stitching) is applied to the peripheral edge of the floor mat 10 with the sewing thread 70 and the upper and lower looper threads 71 and 72, and the mat substrate 12 on the front and back sides of the upper and lower looper threads 71 and 72 as a covering portion. Both ends (the end portion 71A on the front side of the mat base material 12 in the upper looper yarn 71 and the end portion 72A on the back side of the mat base material 12 in the lower looper yarn 72) are connected by the sewing thread 70 (sewing step).

  Here, the sewing thread 70 passes through the mat base material 12 and is sewn so as to be positioned away from the side surface portion 12A of the mat base material 12 from the front surface 112 side to the back surface 212 side of the mat base material 12. Therefore, the seam allowance on the surface side of the floor mat 10 can be shortened (for example, within 3 mm), and the peripheral portion can be integrated with the central portion while protecting the peripheral portion of the floor mat 10. It becomes. Further, in the vehicle interior, the floor mat 10 and its surroundings can be expressed with a sense of unity in terms of design.

  Further, since the seam allowance on the surface side of the floor mat 10 is short, that is, the amount of the pile 19 is small, even if the pile 19 is high or has a large amount of fabric weight, the thickness of the overlock stitched portion is reduced. The pile 19 can be prevented from protruding from between the upper looper yarns 71.

  Furthermore, as shown in FIG. 6, the sickle-like portion of the presser plate 48 is elongated, so that the state of the pile 19 can be easily confirmed, so that the visual workability of the sewing manufacturer is improved and the desired position is reached. Can be easily sewn. Further, since the sickle-shaped portion of the pressing plate 48 is elongated, the pile 19 can be pressed by the inward resilience of the floor mat 10.

The presser plate 48 may be formed of a highly transparent material in consideration of the visual workability of the sewing manufacturer. In this case, the sixth embodiment of the mat material sewn by the mat material sewing apparatus is used. As shown in FIG. 9, the sickle-like portion of the pressing plate 48 may have a slightly wider configuration. The sixth embodiment is an embodiment of the present invention.

Next, a seventh embodiment of the mat material sewn by the mat material sewing apparatus will be described with reference to FIGS. The seventh embodiment is an embodiment of the present invention. The same members as those in the first to sixth embodiments are denoted by the same reference numerals, and the description thereof is omitted. Further, the ruler 41 as the positioning means has substantially the same configuration as the ruler 42 in the fifth and sixth embodiments except for the points described below.

  As shown in FIG. 10, the sewing apparatus 40 includes a ruler 41, and the ruler 41 is arranged on the side where the floor mat 10 is arranged (FIG. 11, in the drawing, as shown in FIGS. 10 and 11). An inclined portion 41A is formed at the lower part on the front side. As shown in FIG. 11, the inclined portion 41A is provided wide along the mat feeding direction (arrow S direction), and as shown in FIG. 10, the end of the mat substrate 12 (the right end of FIG. 10). The bottom surface of the floor mat 10 is inclined with the lower surface of the portion) supported.

  On the arrangement side of the floor mat 10 in the abutment ruler 41, the mat base 12 is positioned with respect to a direction (left-right direction in FIG. 10) that is applied to the lower portion of the side surface portion 12A of the mat base 12 and perpendicular to the sewing progress direction. The wall portion 41B is projected upward. As shown in FIG. 11, the wall portion 41B is provided in the vicinity of an intermediate portion in the width direction of the inclined portion 41A (the left-right direction in FIG. 11).

  From the upper part of the wall part 41B, the overhang | projection part 41C which protruded in hook shape toward the arrangement | positioning side (front side of FIG. 11) of the floor mat 10 (refer FIG. 10) is formed. As shown in FIG. 10, the overhanging portion 41 </ b> C comes into contact with the upper surface (the base portion side portion 118 </ b> A of the side surface portion 118 of the skin layer 18) of the end portion (the right end portion in FIG. 10) of the floor mat 10 from above. It is like that. The overhanging portion 41C, the wall portion 41B, and the inclined portion 41A of the ruler 41 are substantially U-shaped as a whole, and sandwich the base material side portion 118A of the side surface portion 118 of the mat base material 12 and the skin layer 18. This ensures that the posture is maintained.

  At the sewing position, the sewing needle 62 attached to the needle support 63 at the lower end of the needle bar 64 moves up and down in a direction (vertical direction) perpendicular to the needle plate 45 (see FIG. 7). As a result, the sewing mechanism 60 moves the sewing machine in a locus that moves away from the side surface portion 12A of the mat base material 12 toward the back surface 212 side of the mat base material 12 with respect to the end portion of the floor mat 10. The needle 62 is reciprocated to sew.

  In this way, by tilting the end of the floor mat 10, the sewing thread 70 can be moved up and down in the direction (vertical direction) perpendicular to the needle plate 45 (see FIG. 7) even if the sewing thread 70 is moved up and down. The mat substrate 12 is sewed through the mat substrate 12 so as to move away from the side surface portion 12A of the mat substrate 12 from the front surface 112 side to the back surface 212 side.

Next, an eighth embodiment of the mat material sewn by the mat material sewing apparatus will be described with reference to FIG. The eighth embodiment is an embodiment of the present invention. The eighth embodiment is characterized in that the sewing needle 62 (see FIG. 8) in the fifth embodiment is a sewing needle 61 as an arc-shaped sewing needle, and the sewing needle 61 is reciprocated in an arc shape. Other configurations are substantially the same as those of the fifth embodiment, and thus the same reference numerals are given and description thereof is omitted.

  As shown in FIG. 12, the arc-shaped sewing needle 61 is attached to the needle support 63 at the lower end of the needle bar 64. The needle bar 64 is connected to a drive motor 68 via a needle bar crank mechanism 67, and reciprocates in an arc shape via the needle bar crank mechanism 67 when the drive motor 68 is driven.

  The sewing mechanism 60 has a sewing needle 61 with an arc locus that is located away from the side surface portion 12A of the mat base material 12 toward the back surface 212 side of the mat base material 12 with respect to the end portion of the floor mat 10. The sewing machine is designed to reciprocate and sew.

  An entry angle M of the sewing needle 61 to the floor mat 10, that is, a tangent line at the entry point of the sewing needle 61 to the floor mat 10 in the arc locus of the sewing needle 61 is formed between the surface 112 of the mat base material 12. The approach angle M is preferably set to 20 ° ≦ M ≦ 80 °. In the present embodiment, M = 65 ° is set as the optimum value.

  By the sewing by the sewing mechanism 60, the sewing thread 70 moves the mat base material 12 in an arc shape so that the sewing thread 70 moves away from the side surface portion 12A of the mat base material 12 from the front surface 112 side to the back surface 212 side. Can be passed through and sewn. Thereby, a seam allowance can be shortened.

Next, a ninth embodiment of the mat material sewn by the mat material sewing apparatus will be described with reference to FIG. The ninth embodiment is an embodiment of the present invention. Moreover, about the same member as 1st-8th embodiment, the same code | symbol is attached | subjected and description is abbreviate | omitted.

  As shown in FIG. 13, the sewing apparatus 40 includes the ruler 41 described in the seventh embodiment, and the edge of the floor mat 10 (the right side edge in FIG. 13) is inclined by the ruler 41. Support in the state. The sewing mechanism 60 is similar to the mechanism described in the eighth embodiment, and performs sewing by reciprocating the arc-shaped sewing needle 61 in an arc shape.

  Thereby, it is possible to perform reliable sewing with a short seam allowance, and it is possible to obtain a floor mat 10 in which the peripheral portion has integrity with the central portion while protecting the peripheral portion of the floor mat 10 by sewing. .

  In addition, various base fabrics, such as a nonwoven fabric and a nib, can be applied to the base fabric 14 in the said 5th-9th embodiment.

  Further, in the fifth to ninth embodiments, the sewing needles 61 and 62 are sewn from the surface side of the floor mat 10 and are sewn, but two of FIGS. 8, 10, 12, and 13 are used. It is good also as a structure which makes it approach from the back surface 212 side of the floor mat 10, and sews like the sewing needles 61 and 62 shown with the dashed-dotted line.

  Further, in the fifth to ninth embodiments, the sewing device 40 performs overlock stitching (edge stitching), and the covering portion is formed by the upper and lower looper threads 71, 72. Other covering portions such as a material may be used, and both end portions of the other covering portions on the front and back sides of the mat base 12 may be connected by sewing threads by sewing.

  Furthermore, a ruler (not shown) having a configuration in which the inclined portion 41A is excluded from the ruler 41 (see FIG. 11 and the like) in the seventh and ninth embodiments is used as the fifth, sixth, and eighth. As an alternative to the ruler 42 in the embodiment, the present invention may be applied to the fifth, sixth, and eighth embodiments.

  In the first to ninth embodiments, the case where the side portion of the base material is the side surface portion 12A of the mat base material 12 has been described as an example. It is not limited to a planar side portion as in a case where the cut surface is perpendicular to the front and back surfaces, and may be a side portion other than the planar shape (for example, formed in an uneven shape).

It is a sectional view showing a mat member according to the first embodiment (embodiment of the present invention). FIG. 1A shows a state before sewing. FIG. 1B shows a state after sewing. It is a perspective view of a half section showing a mat member according to the first embodiment. It is a sectional view showing a mat member according to a second embodiment (embodiment of the present invention). Third Embodiment is a sectional view showing a mat member according to (an embodiment of the present invention). It is a sectional view showing a mat member according to a fourth embodiment (reference example). In 5th Embodiment ( embodiment of this invention) , it is a perspective view which shows the state by which a mat | matte material is sewn with the sewing apparatus of a mat | matte material. Is a perspective view showing a main portion of the sewing device of the mat member according to the fifth embodiment. In 5th Embodiment, it is sectional drawing which shows the state by which a mat material is sewn by the sewing apparatus of a mat material. In 6th Embodiment ( embodiment of this invention) , it is a perspective view which shows the state by which a mat | matte material is sewed by the sewing apparatus of a mat | matte material. In 7th Embodiment ( embodiment of this invention) , it is sectional drawing which shows the state by which a mat material is sewn by the sewing apparatus of a mat material. Is a perspective view showing a main portion of the abutting scale in the seventh embodiment. In 8th Embodiment ( embodiment of this invention) , it is sectional drawing which shows the state by which a mat | matte material is sewed by the sewing apparatus of a mat | matte material. In 9th Embodiment ( embodiment of this invention) , it is sectional drawing which shows the state by which a mat | matte material is sewed by the sewing apparatus of a mat | matte material.

Explanation of symbols

10 Floor mat (mat material)
12 Matt base material (base material)
12A Side surface of mat substrate (side of substrate)
12B Back surface edge of mat substrate (back surface edge of substrate)
18 Skin layer
19 Pile 20 Perimeter protection (end protection)
22 Decorative yarn (covering part)
28 Tape material (coating part)
30 Mall (coating part)
112 surface 118 side surface portion of skin layer 118A base material side portion 212 back surface A diagonal inward direction from the surface of the mat base material to the back surface (direction from the surface of the base material to the back surface)
Y Thickness direction from the surface of the mat substrate to the back surface (direction from the surface of the substrate to the back surface)

Claims (1)

A substrate;
Is supported by the base, the table cortex cormorants covering the surface of the substrate to the distal portion provided with the pile flexible with consists of a pile of a number of fibrous erected relative to said base member When,
The base material of the skin layer, which is provided with a covering portion that integrally covers the base portion side portion of the side surface portion of the skin layer, the side portion of the base material, and the back end portion of the base material, and is covered with the covering portion. By pressing and holding the side part in the direction from the front surface to the back surface of the base material, the restoring force of the pile densely inside the side surface portion of the skin layer of the pile is applied to the skin layer. End protection means for bending and warping the side surface portion of the skin layer so as to cover the upper side of the covering portion at the upper portion of the side surface portion of
Have
The end protection means includes a sewing thread that penetrates the base material and connects both end portions of the covering portion on the front and back sides of the base material by sewing, and both end portions of the covering portion connected by the sewing are the The base material side portion of the skin layer and the base material are sandwiched, and the sewing thread is positioned away from the side portion of the base material as it goes from the front surface side to the back surface side of the base material. Mat material to be used.

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