JP5584562B2 - Automotive floor mat - Google Patents

Description

  The present invention relates to an automobile floor mat.

  2. Description of the Related Art Conventionally, in an automobile, a floor mat is laid in order to prevent soil, sand, mud, gravel, or the like adhering to shoes or the like from adhering to the floor in the automobile and soiling the floor.

  As this floor mat, a material comprising a skin material such as a carpet and a backing material for supporting the skin material is known. Since this skin material has been used for many years, it will fall down, wear, etc., and the appearance will be significantly impaired. Therefore, a heel pad material is adhered on the skin material to protect the skin material (Patent Document 1). . However, when a relatively hard heel pad material such as vulcanized rubber or thermoplastic elastomer with excellent wear resistance as the heel pad material is bonded to the skin material, the portion where the heel pad material is bonded is compared to the portion where it is not bonded. The tendency to become hard was strong. On the other hand, in recent years, it has been pointed out that there is a danger that the floor mat becomes hard as a result of the heel pad material being adhered, and as a result, it is easily caught on the accelerator pedal.

JP-A-11-28145

  The present invention has been made under such circumstances, and an object thereof is to provide a floor mat that is excellent in flexibility despite having a heel pad.

The invention according to claim 1 of the present invention is “a floor mat for an automobile having a skin layer made of carpet, wherein two or more heel pads smaller than the heel movement region are spaced apart in the heel movement region of the skin layer. Heel pads having incompletely separated bends are disposed in two or more areas that are smaller than the flexible bends or the heel movement area, and the heel movement area is laid on a floor mat for an automobile An automobile floor mat, which is sometimes bendable by a force from the front-rear direction of the automobile or the diagonally right-back direction of the right side. "

  In the invention according to claim 1 of the present invention, when two or more heel pads smaller than the heel movement region are arranged, when a force from the front-rear direction of the automobile or the diagonally right-back direction is applied between the heel pads, This is an automotive floor mat that can be bent and has excellent flexibility.

  In addition, when a heel pad having a bent portion that is incompletely separated is disposed in two or more areas smaller than the heel movement area, when a force from the front-rear direction of the automobile or the diagonally right-back direction is applied An automotive floor mat that can be bent at a bent portion and has excellent flexibility.

  As described above, the automobile floor mat according to the present invention is excellent in flexibility to bend when a force from the front-rear direction or the right oblique front-rear direction of the automobile is applied, and thus is difficult to be caught by an accelerator pedal, a brake pedal, or the like. In addition, even if the automobile floor mat is caught on an accelerator pedal, a brake pedal, or the like, malfunction of the automobile can be suppressed and safety can be improved.

Schematic top view from the skin layer side showing the state where the heel pad is placed 拡 大 Enlarged view of moving area Top view of specimen used for evaluation of flexibility Conceptual diagram of flexibility test method (A) Schematic top view from the skin layer side showing the heel pad arrangement state (b) Schematic top view from the skin layer side showing another heel pad arrangement state (c) The heel pad Schematic top view from the skin layer side showing yet another arrangement state (d) Schematic top view from the skin layer side showing still another arrangement state of the heel pad (e) Still another heel pad view Schematic top view from the skin layer side showing the arrangement state of Schematic top view from the skin layer side showing the arrangement of the bent part in the heel pad (A) Schematic top view from the skin layer side showing the arrangement state of another bent portion in the heel pad (b) Schematic view from the skin layer side showing the arrangement state of another bent portion in the heel pad Top view Schematic top view from the skin layer side showing the arrangement state of still another bent part in the heel pad Schematic top view from the skin layer side showing the arrangement state of still another bent part in the heel pad Schematic top view from the skin layer side showing the arrangement state of still another bent part in the heel pad (A) Schematic top view showing the cutting dimensions of the heel pad used in Example 2 (b) Schematic top view showing the cutting dimensions of the heel pad used in Example 3 (c) Used in Example 4 Schematic top view showing the cutting dimensions of the heel pad

  The automobile floor mat (hereinafter sometimes simply referred to as “mat”) of the present invention has a carpet as a skin layer that can be seen with eyes when the mat is laid. Examples of the carpet include Unicom, Wilton carpet, Akisminster carpet, double face carpet, hook drag, tufted carpet, flock carpet, cord carpet, and knit carpet. Among these, a tufted carpet is preferable. In the case of a tufted carpet, the pile may be a cut pile, a loop pile, or a mixture of these. The material constituting the carpet of the present invention is not particularly limited, but is preferably nylon, polypropylene, polyethylene terephthalate, or polytrimethylene terephthalate. In addition, materials using biomass such as polylactic acid that are environmentally friendly can also be used.

  In the case of a suitable tufted carpet, the gauge of the tufted carpet is not particularly limited because it depends on the tuft machine, but generally 1 / 10G, 1 / 8G, 5 / 32G, etc. can be used. it can. However, it may have other standards. In addition, since the strength of the carpet decreases when the number of stitches is large, it is preferably 20 (ST / inch) or less. If the number is small, the base fabric is easily visible and the appearance is impaired, so 5 (ST / inch) or more. Is preferred. Further, the pile material is not particularly limited, but nylon, polypropylene, polyethylene terephthalate, and polytrimethylene terephthalate are preferable. Also, a pile using biomass such as polylactic acid in consideration of the environment may be used.

  Although the mat of the present invention can be composed only of a skin layer made of carpet, the mat is preferably mounted on an automobile floor (usually a carpet), so that the mat preferably exhibits a non-slip action. For this reason, the mat preferably has a backing layer that exhibits an anti-slip action. As such a backing layer, for example, (a) a resin protrusion is partially provided on the contact surface with the nonwoven fabric floor, and (b) a flame is irradiated on the contact surface side with the nonwoven fabric floor. The fibers are melted and solidified to form a resin lump, (c) irregularities formed on the contact surface side with the foam floor, or Examples thereof include those in which a pressure-sensitive adhesive is applied in a linear form, and (e) those in which protrusions are partially provided on the contact surface with the floor of vulcanized rubber or thermoplastic elastomer.

  Moreover, a nonwoven fabric layer and a foam layer can be provided between the backing layer and the skin layer. Various functions can be imparted by the presence of such a nonwoven fabric layer or foam layer. For example, sound absorption performance can be improved.

  The mat of the present invention has a skin layer made of carpet, so that the appearance is remarkably impaired, for example, a hole is opened due to wear or the like. In particular, in the case of tufted carpet, the appearance deteriorates remarkably, such as falling down due to long-time operation and opening of holes due to wear or the like. Therefore, in the present invention, (1) two or more heel pads smaller than the wrinkle movement area are arranged in the wrinkle movement area of the skin layer (first aspect), or (2) wrinkle movement of the skin layer In the region, heel pads having bent portions that are incompletely separated are arranged in two or more regions smaller than the heel movement region (second mode). In the case of the mat of the first aspect, since it has the flexibility to bend between the heel pads by the force from the front-rear direction of the automobile or the diagonally right-back direction, it is difficult to be caught on the accelerator pedal and the brake pedal. Even if the mat is caught on the brake pedal or the like, the malfunction of the automobile can be suppressed. Similarly, in the case of the mat according to the second aspect, since it has the flexibility to bend at the bent portion by the force from the front-rear direction of the vehicle or the right front-rear direction, it is difficult to be caught by the accelerator pedal or the brake pedal. Even if the mat is caught on a pedal, a brake pedal or the like, malfunction of the automobile can be suppressed.

(First aspect)
First, FIG. 1 shows a schematic top view from the skin layer side showing a state in which two or more heel pads are arranged.

  In the mat M of FIG. 1, a total of 12 square heel pads HP, which are arranged in four rows in the width direction W of the vehicle and three columns in the length direction L of the vehicle, are arranged. Therefore, when a force is applied to the mat M in the longitudinal direction L of the automobile (the longitudinal direction Zd of the automobile), it is bent between the first row and the second row and between the second row and the third row. Flexibility is possible. Also, when a force is applied to the mat M in the width direction W of the car, between the first and second lines, between the second and third lines, and between the third and fourth lines. It also has the flexibility to bend.

  Note that one heel pad HP in FIG. 1 is formed of a square with one side having a length of approximately four divisions of the heel movement area HA (the heel movement area HA in the vehicle width direction W). When a force is applied, the size of one heel pad HP should be smaller than the heel movement area HA so that the heel pad HP has flexibility to bend, particularly by the force from the longitudinal direction Zd of the automobile or the diagonally rightward longitudinal direction Md. Although not particularly limited, it is preferable that the size is not more than one half of the total surface area of the heel pads. The smaller the size of one heel pad HP, the more the number of bent portions. Therefore, it is preferable that the size of the heel pad is equal to or less than one-fourth of the total surface area of the heel pads, and the size of the heel pad is equal to or less than one-sixth of the total surface area of the heel pads. And more preferable. On the other hand, from the viewpoint of durability and workability of the heel pad itself, the size of one heel pad HP is preferably at least one-twentieth of the total sum of one surface area of the heel pad.

  Moreover, although the heel pad HP in FIG. 1 is square, it does not need to be square. For example, it can be a rectangle, a circle, an ellipse, or a polygon. More specifically, as shown in FIGS. 5A to 5E, it may be a triangle or a trapezoid.

  Further, in the case of a polygonal shape such as a polygon, it is also effective to round the corners so that the heel pad HP is difficult to peel from the skin layer. However, it is preferably approximately square or rectangular so that the pile is not easily exposed between the heel pads. When the heel pad HP is rectangular, the heel pad HP has a short side and the length of the vehicle so that the heel pad HP is easily bent when a force is applied in the longitudinal direction L of the vehicle (the longitudinal direction Zd of the vehicle). It is preferable to arrange so that the length direction L coincides.

  Further, twelve heel pads HP in FIG. 1 are arranged, but two or more heel pads HP can be bent when a force is applied to the mat M from the front-rear direction Zd or the right front-rear direction Md of the vehicle. The number is not particularly limited. Moreover, although the heel pad HP in FIG. 1 is arranged in a lattice shape, it does not have to be in a lattice shape and can be arranged in a staggered manner. The staggered arrangement facilitates bending when a force is applied from the right diagonal front-rear direction Zd. Note that the heel movement area and the heel pad arrangement area do not have to be completely coincident with each other as long as they are substantially coincident as shown in FIG.

  In the present invention, the “saddle movement region” is a region in which the soot moves during a driving operation. For example, referring to FIG. A straight line parallel to L (Lr), passing approximately the left end of the brake pedal, a straight line parallel to the longitudinal direction L of the vehicle (Ll), and if the accelerator pedal is an organ type, passing through its fulcrum, the vehicle width direction W If the accelerator pedal is a suspension type, it passes through the intersection of the extension surface of the accelerator pedal surface when the accelerator pedal is fully depressed and the floor mat, and the width direction W of the vehicle It is a region surrounded by a parallel straight line (Lf) and a straight line (Lb) parallel to the straight line Lf and separated by 300 mm.

  In the case of a manual vehicle, although not shown, like an automatic vehicle, the vehicle passes through the right end of the accelerator pedal, a straight line (Lr) parallel to the longitudinal direction L of the vehicle, and passes through the left end of the clutch pedal. A straight line (Ll) parallel to the length direction L of the vehicle, when the accelerator pedal is an organ type, it passes through its fulcrum, and is a straight line (Lf) parallel to the width direction W of the vehicle. Includes a straight line (Lf) parallel to the width direction W of the automobile passing through the intersection of the extended surface of the accelerator pedal surface and the floor mat when the accelerator pedal is stepped on, and a straight line parallel to the straight line Lf and separated by 300 mm. This is a region surrounded by (Lb).

  When the carpet of the mat of the present invention is a tufted carpet, the heel pad is separated from the heel pad adjacent in the pile gauge direction by a distance of 3 gauge or less, and the heel pad adjacent in the pile stitch direction is Are preferably spaced apart by a distance of 5 stitches or less. By arranging in this way, there are few piles of tufted carpet exposed from between adjacent heel pads, so that the tufted carpet can be protected and the appearance can be maintained.

Here, a description will be given based on FIG. 2 which is an enlarged view of the eyelid movement region. For example, the HP ₂₂ that is the heel pad in the second row and the second column is arranged at a distance of 5 stitches or less from the HP ₂₁ or HP ₂₃ adjacent to the stitch direction SD of the pile. Therefore, when a force is applied in the stitch direction SD, it can be bent between the HP ₂₁ and the HP ₂₂ and between the HP ₂₂ and the HP _23, and between the HP ₂₁ and the HP ₂₂ and between the HP ₂₂ and the HP ₂₂ . Since it is relatively narrow with the HP ₂₃ and there are few exposed piles, the tufted carpet can be protected and the appearance can be maintained. Similarly, the HP ₂₂ is arranged at a distance of 3 gauge or less from the HP ₁₂ or HP ₃₂ adjacent to the pile gauge direction GD. Therefore, when a force is applied in the gauge direction GD, it can be bent between HP ₁₂ and HP _22, and between HP ₂₂ and HP _32, and between HP ₁₂ and HP ₂₂ , and HP ₂₂ and Since it is relatively narrow with the HP ₃₂ and there are few exposed piles, the tufted carpet can be protected and the appearance can be maintained.

  In FIG. 2, the gauge direction GD and the stitch direction SD are spaced at equal intervals. However, as long as the gap is satisfied, the gaps do not have to be at equal intervals, and in the gauge direction GD and / or the stitch direction. In SD, it can also be spaced apart at irregular intervals. Moreover, although it is spaced apart at equal intervals in the gauge direction GD or the stitch direction SD, it may be spaced apart at irregular intervals in the stitch direction SD or the gauge direction GD.

  In the gauge direction GD, if the adjacent heel pads are separated by a distance of 3 gauge or less, it is easy to protect the tufted carpet. On the other hand, even if adjacent heel pads are in contact with each other, they may be in contact with each other because they can be bent between adjacent heel pads, but the adjacent heel pad distance is 2 gauge or more so that they can be bent easily. Is preferred. The “gauge direction” is a production direction of tufted carpet.

  Further, in the stitch direction SD, if the adjacent heel pads are separated by a distance of 5 stitches or less, it is easy to protect the tufted carpet. On the other hand, even if adjacent heel pads are in contact with each other, they can be bent between adjacent heel pads, so they may be in contact, but the adjacent heel pad distance is 2 stitches or more so that they can be bent easily. Is preferred. Note that the “stitch direction” is a generally-known lateral direction that is swung by 90 ° with respect to the production direction of the tufted carpet.

  The gauge direction of the tufted carpet may coincide with the length direction L (front-rear direction Zd) of the automobile or may coincide with the width direction W of the automobile, and the direction is not particularly limited. Absent. Similarly, the stitching direction of the tufted carpet may coincide with the length direction L (front-rear direction Zd) of the automobile or may coincide with the width direction W of the automobile, and the direction is particularly limited. is not.

  In addition, the heel pad in the present invention is not particularly limited as long as it can protect the pile of the tufted carpet, but it is preferable that the heel pad itself has high wear resistance. For example, the heel pad can be composed of a tufted carpet made of thermoplastic elastomer, vulcanized rubber, preferably nylon pile backed (eg, with polyethylene resin) and the like. The material may be different for each heel pad.

  Thus, in the case of tufted carpet, the heel pad adjacent in the pile gauge direction is separated by a distance of 3 gauge or less, and the heel pad adjacent in the pile stitch direction is 5 stitches or less. However, in the case of a carpet other than a tufted carpet, it is 5-12 mm apart so that the carpet can be easily protected and bent in any direction from the adjacent heat pad. It is preferable.

Next, a schematic top view from the skin layer side showing another arrangement state of the heel pads is shown in FIG. In FIG. 5A, a triangular heel pad HP ₁ and a trapezoidal heel pad HP ₂ are provided, and the triangular heel pad HP ₁ is a heel movement region in the front right direction of the vehicle in the heel movement region. It arranges so that the corner part may be constituted. As described above, since the triangular heel pad HP ₁ and the trapezoidal heel pad HP ₂ are arranged, the carpet is exposed in a straight line descending to the right from the front to the rear of the automobile. Therefore, when a force is applied to the mat M from the diagonally right and left front direction Md of the automobile, the heel pad HP ₁ and the trapezoidal heel pad HP with no heel pad and the carpet exposed are present. ₂ has flexibility to bend.

In FIG. 5A, a triangular heel pad HP ₁ and a trapezoidal heel pad HP ₂ are arranged, that is, heel pads having different shapes and different sizes are combined. Heel pads of the same size can be combined. For example, as shown in FIG. 5B, heel pads having the same triangular shape and the same size can be combined. Also in this case, when a force is applied to the mat M from the right and left front-rear direction Md with respect to the front-rear direction Zd of the automobile, the heel pad HP _{1 having} no heel pad and exposing the carpet is present. And a heel pad HP ₂ having a triangular shape.

In FIG. 5A, the triangular heel pad HP ₁ is arranged so as to constitute the corner portion of the heel movement area in the front right direction of the automobile in the heel movement area. As shown in FIG. 4, the triangular heel pad HP ₂ can be arranged so as to constitute a corner portion of the heel movement area at the left rear of the heel movement area. Also in this case, when a force is applied to the mat M from the right oblique front-rear direction Md, the heel pad does not exist, and the carpet is exposed and has flexibility to bend between the heel pads.

Further, in FIG. 5 (a), two triangular heel pads HP ₁ and trapezoidal heel pads HP ₂ are arranged, but as shown in FIG. 5 (d), triangular small heels are arranged. _Three pads, a pad HP ₁ , a trapezoidal heel pad HP ₂ , and a triangular large heel pad HP ₃ can also be arranged. In this case, when a force is applied to the mat M from the right and left front-rear direction Md of the automobile, the heel pad does not exist and the carpet is exposed, and the triangular small heel pad HP ₁ and the trapezoidal heel are provided. It has flexibility to bend at two places between the pad HP ₂ and between the trapezoidal heel pad HP ₂ and the triangular heel pad HP ₃ .

Similarly, as shown in FIG. 5 (e), four triangular heel pads HP ₁ and HP ₄ and two trapezoidal heel pads HP ₂ and HP ₃ can be arranged. In this case, when a force is applied to the mat M from the diagonally right and left forward direction Md of the automobile, the heel pad HP ₁ and the trapezoidal heel pad in which the heel pad does not exist and the carpet is exposed are present. Flexibility to bend at three locations between the HP ₂ , between the trapezoidal heel pads HP ₂ and HP ₃ , and between the trapezoidal heel pad HP ₃ and the triangular heel pad HP ₄ . . Thus, since the part which can be bent increases, so that the number of heel pads increases, it is excellent in the softness | flexibility.

  Although the size of one heel pad in FIGS. 5A to 5E is not particularly limited, the smaller the size of one heel pad, the easier it is to bend with a small force. In order to be flexible and excellent in flexibility, it is preferable that at least one heel pad has a size not larger than one quarter of the total surface area of the heel pads, and not larger than one sixth of the total surface area of the heel pads. More preferably, the size of On the other hand, from the viewpoint of durability and workability of the heel pad itself, even the smallest heel pad preferably has a size that is at least one-twentieth of the sum of the single surface areas of the heel pad.

  In addition, since the heel pad shape in FIGS. 5A to 5E is a cornered shape such as a triangle or a trapezoid, it is also effective to round the corners so that the heel pad is difficult to peel off from the skin layer. is there.

  Even in such a case as shown in FIGS. 5A to 5E, the adjacent heat pad is easy to protect the carpet and bend easily in any direction. It is preferably 12 mm apart.

  In such a mat of the present invention, two or more heel pads smaller than the heel movement area are arranged in the heel movement area after the carpet is manufactured by a conventional method. In addition, it arrange | positions so that it can be bent by the force from the front-back direction Zd of a motor vehicle, or right diagonal front-back direction Md. In the case of tufted carpet, the heel pad adjacent in the gauge direction of the pile is separated by a distance of 3 gauge or less, and the heel pad adjacent in the stitch direction of the pile is separated by a distance of 5 stitches or less. Is preferably arranged. In the case of other carpets, it is preferable to dispose the carpet in a state of being 5 to 12 mm apart in any direction from the adjacent heat pad.

  Then, after fixing the heel pad by high-frequency fusion, fusion with hot meter resin, or ultrasonic fusion, the periphery can be formed into a desired shape. It is also possible to form a mat by arranging the heel pad after the periphery of the carpet is formed into a desired shape and fixing the heel pad in the same manner. In addition, when a layer (for example, a backing layer) other than the carpet layer is provided, it is fused with a hot melt resin before or after the heel pad is disposed, or the peripheral portion of the mat is overlocked. It can be laminated and integrated by processing, tape processing or fusion processing, and manufactured in the same manner as described above.

(Second aspect)
The second aspect of the present invention will be described with reference to FIG. 6, which is a schematic top view from the skin layer side, showing the arrangement state of the bent portions in the heel pad.

The heel pad HP in FIG. 6 extends in the lower right direction in the vertical direction (front-rear direction Zd of the vehicle) in the drawing with respect to the rectangular heel pad HP having a size corresponding to the heel movement region 4. The first slit group Th ₁ , Th ₃ , Th ₅ , Th ₇ and four second slit groups Th ₂ , Th ₄ , Th ₆ , Th ₈ extending in the upper left direction, and the first slit group The slits of the second slit group and the slits of the second slit group are arranged alternately. As described above, the slits of the first slit group and the second slit group are not completely separated but incompletely separated into an area smaller than the heel movement area. Therefore, as apparent from FIG. 6, the heel pad is not separated, and is in a zigzag-like state, so that it is excellent in handleability as a single heel pad. When a force is applied to the mat M having such a heel pad HP from the right oblique front-rear direction Md of the automobile, it can be bent at each slit of the first slit group and the second slit group. Excellent flexibility.

  In addition, as shown in FIG. 6, it has a bending part so that it may isolate | separate into two or more area | regions smaller than a heel movement area | region, and it is force with respect to the mat M from the front-back direction Zd of a motor vehicle, or right diagonally front-back direction Md. By extending the bent portion and the region that is substantially separated only by the outer periphery or the bent portion, that is, the bent portion (in the case of FIG. 6, the slit) so that it can be bent and has excellent flexibility. The size of the region when completely separated is preferably less than or equal to one-half of the total surface area of the heel pads, and is less than or equal to one-fourth of the total surface area of the heel pads. It is preferable that the size is not more than 1/6 of the total sum of the single surface areas of the heel pad. On the other hand, from the viewpoint of durability and workability of the heel pad itself, the size of the region is preferably at least one-twentieth of the total sum of the single surface areas of the heel pad.

  In FIG. 6, slits (bent portions) extend in the lower right direction and the upper left direction with respect to the vertical direction (the longitudinal direction Zd of the automobile) in the drawing, but may extend in the horizontal direction in the drawing. For example, it can be bent in the longitudinal direction Zd of the automobile.

  Furthermore, although the heel pad HP in FIG. 6 has eight slits (bent portions), the heel pad HP can be bent with respect to the mat M by a force from the front-rear direction Zd of the automobile or the diagonally right-back direction Md. The number is not particularly limited as long as it has flexibility.

  Further, the width of the slit (bent portion) in the heel pad HP in FIG. 6 is preferably 5 to 12 mm so that the carpet can be easily protected and bent. As in the first embodiment, the heel pad HP shown in FIG. 6 can be composed of a thermoplastic elastomer, a vulcanized rubber, preferably a carpet tufted with a nylon pile or the like backed (for example, with polyethylene resin).

In FIG. 6, the slits of the first slit groups Th ₁ , Th ₃ , Th ₅ , Th _{7 and} the slits of the second slit groups Th ₂ , Th ₄ , Th ₆ , Th ₈ are staggered. Arranged but not necessarily staggered. In FIG. 6, the first slit groups Th ₁ , Th ₃ , Th ₅ , Th ₇ extend in the lower right direction in the drawing, and the second slit groups Th ₂ , Th ₄ , Th ₆ , Th ₈ are Although it extends in the upper left direction in the drawing, any of the slits may extend in the same direction.

FIG. 7A is a schematic top view from the skin layer side showing the arrangement state of the bent portion in the heel pad, regarding another aspect of the second aspect. The heel pad HP of FIG. 7A has slit-like through holes (bent portions) TH _{1 to} Th ₈ in the lower right direction (or upper left direction) with respect to the vertical direction (front-rear direction Zd of the automobile) in the drawing. The only difference is that the through holes (bent portions) TH _{1 to} Th ₈ do not reach the outer periphery of the heel pad. Similarly to the heel pad of FIG. 6, the heel pad shown in FIG. 7A is not completely in a region smaller than the heel movement region but incompletely due to the slit-like through holes (bent portions) TH _{1 to} Th ₈ . Since it is separated, as is clear from FIG. 7A, the heel pad is not separated and the outer periphery is in a connected state, so that it is excellent in handleability as one heel pad. When a force is applied to the mat M on which such a heel pad HP is disposed from the right oblique front-rear direction Md of the automobile, the slit-shaped through holes (bent portions) TH _{1 to} Th ₈ act as the bent portions. Because it can, it is excellent in flexibility.

  The heel pad HP in FIG. 7A is the same as the heel pad in FIG. 6 except for the above points.

FIG. 7 (b), which is a schematic top view from the skin layer side, shows the arrangement state of the bent portions in the heel pad for another embodiment. The 7 heel pad HP slit-like through holes of (b) (bent portion) TH ₁ to TH ₄ is the drawing, only points that are present only in the region of the upper right in FIG. 7 (a) and Is different. Similarly to the heel pad of FIG. 7A, the heel pad shown in FIG. 7B is not completely formed in a region smaller than the heel movement region by the slit-like through holes (bent portions) TH _{1 to} Th ₄ . Since it is incompletely separated, the heel pad is not separated, as is clear from FIG. 7B, and the outer periphery of the upper right area and the lower left area are connected. Excellent handleability as one heel pad. When a force is applied to the mat M on which such a heel pad HP is disposed from the right oblique front-rear direction Md of the automobile, the slit-like through holes (bent portions) TH _{1 to} Th ₄ act as the bent portions. Because it can, it is excellent in flexibility.

  The heel pad HP shown in FIG. 7B is different from the heel pad shown in FIG. 6 or FIG.

Furthermore, about another aspect, it shows in FIG. 8 which is a typical top view from the skin layer side which shows the arrangement | positioning state of the bending part in a heel pad. The heel pad HP in FIG. 8 has slit-like through holes (bent portions) TH _{1 to} Th ₈ extending in the lower right direction with respect to the vertical direction (front-rear direction Zd of the automobile) in the drawing. There are connection portions Co _{1 to} Co ₈ that divide each of the through holes (bent portions) TH _{1 to} Th ₈ into two. Similarly to the heel pad in FIG. 6, the heel pad shown in FIG. 8 is not completely separated into an area smaller than the heel movement area but incompletely separated by slit-like through holes (bent portions) TH _{1 to} Th ₈ . Yes. Further, as is apparent from FIG. 8, the heel pad is not separated, and is connected to the connecting portions Co _{1 to} Co _{8 in} a straight line extending obliquely upward to the right in the drawing. It is easy to handle. When a force is applied to the mat M on which such a heel pad HP is disposed from the right oblique front-rear direction Md of the automobile, the slit-shaped through holes (bent portions) TH _{1 to} Th ₈ act as the bent portions. Because it can, it is excellent in flexibility.

  The heel pad HP shown in FIG. 8 is different from the heel pad shown in FIG. 6 except for the above points.

Furthermore, about another aspect, it shows in FIG. 9 which is a typical top view from the skin layer side which shows the arrangement | positioning state of the bending part in a heel pad. The heel pad HP of FIG. 9 has slit-like through holes (bent portions) TH _{1 to} Th ₈ extending in the lower right direction with respect to the vertical direction (front-rear direction Zd of the automobile) in the drawing. There are connection portions Co _{11 to} Co ₈₂ that divide each of the through holes (bent portions) TH _{1 to} Th ₈ into three. Similarly to the heel pad of FIG. 6, the heel pad shown in FIG. 9 is not completely separated into an area smaller than the heel movement area but incompletely separated by slit-like through holes (bent portions) TH _{1 to} Th ₈ . Yes. As is clear from FIG. 9, the heel pad is not separated and is connected by the connection portions Co _{1 to} Co ₈ , and therefore, the handleability as one heel pad is excellent. When a force is applied to the mat M on which such a heel pad HP is disposed from the right oblique front-rear direction Md of the automobile, the slit-shaped through holes (bent portions) TH _{1 to} Th ₈ act as the bent portions. Because it can, it is excellent in flexibility.

  The heel pad HP in FIG. 9 is different from the heel pad in FIG. 6 except for the above points.

Furthermore, about another aspect, it shows in FIG. 10 which is a typical top view from the skin layer side which shows the arrangement | positioning state of the bending part in a heel pad. The heel pad HP of FIG. 10 has three slit-like thin portions (bent portions) i _{1 to} i ₃ , and in the drawing, the lower right direction (or the upper left direction) with respect to the vertical direction (the longitudinal direction Zd of the automobile). Is growing. As described above, the slit-like thin portions (bent portions) i _{1 to} i ₃ are incompletely separated in the heel pad thickness direction into a region smaller than the heel movement region. When a force is applied to the mat M on which such a heel pad HP is disposed from the right and left front-rear direction Md of the automobile, the slit-like thin portions (bent portions) i _{1 to} i ₃ are thin. Therefore, the rigidity is low and it can act as a bent portion, so that it has excellent flexibility.

  As shown in FIG. 10, it is only necessary to have a slit-like thin part (bent part) so as to be separated into two or more areas smaller than the heel movement area, and the longitudinal direction of the automobile with respect to the mat M A region separated by a slit-like thin portion (bending portion) or a slit-like thin portion (bending) similar to FIG. Part) and the outer periphery, or the area that is almost separated only by the slit-like thin part (bent part), that is, the area when completely separated by extending the bent part is the sum of the single surface areas of the heel pad Is preferably less than one half of the total surface area of the heel pads, preferably less than one quarter of the total surface area of the heel pads, and less than one sixth of the total surface area of the heel pads. In the size of That and more preferable. On the other hand, from the viewpoint of durability and workability of the heel pad itself, the size of the region is preferably at least one-twentieth of the total sum of the single surface areas of the heel pad.

  In FIG. 10, the slit-shaped thin portion extends in the lower right direction (or upper left direction) with respect to the vertical direction (the longitudinal direction Zd of the automobile) in the drawing. If it extends in the right-left direction), it can be bent by the force from the front-rear direction of the automobile.

  Furthermore, although the heel pad HP in FIG. 10 has three slit-like thin portions (bent portions), the force is applied to the mat M from the front-rear direction Zd of the automobile or the diagonally right-back direction Md. The number is not particularly limited as long as it has flexibility to bend when added.

  Furthermore, the width of the slit-like thin portion (bent portion) in the heel pad HP of FIG. 10 is preferably 1 to 5 mm so as to be easily bent. As in the first embodiment, the heel pad HP of FIG. 10 can be composed of a thermoplastic elastomer, a vulcanized rubber, preferably a carpet tufted with a nylon pile or the like backed (for example, with polyethylene resin).

  In addition, arrangement | positioning of the bending part which consists of a thin part is not limited to arrangement | positioning of FIG. 10, It can be bent by arrange | positioning similarly to FIGS. In addition, if the thin wall portion is formed by pressing a heel pad with a uniform thickness, the thin wall portion tends to become hard due to pressurization. Preferably there is.

  The “bending part” of the present invention is a part that is incompletely separated into two or more areas smaller than the saddle movement area, and the force is applied to the mat from the longitudinal direction Zd of the automobile or the diagonally forward and backward direction Md. When added, it is the part that preferentially bends. As the bent portion, for example, a slit as shown in FIG. 6, a (slit-like) through-hole as shown in FIGS. 7A and 7B, a (slit-like) thin-walled portion as shown in FIG. 10, and the surface direction of the heel pad Incisions that are incompletely separated from each other, incisions that are incompletely separated in the thickness direction of the heel pad, or a combination thereof. As described above, when “incompletely separated” is connected to somewhere, it can be handled as a single heel pad and has excellent handleability.

  The mat according to the present invention is manufactured by a conventional method, after a carpet is manufactured, a heel pad having a bent portion as described above is disposed in the heel movement region, then high frequency fusion, fusion with hot meter resin, ultrasonic After fixing the heel pad by fusion, the periphery can be formed into a desired shape. It is also possible to form a mat by arranging the heel pad after the periphery of the carpet is formed into a desired shape and fixing the heel pad in the same manner. In addition, when a layer (for example, a backing layer) other than the carpet layer is provided, it is fused with a hot melt resin before or after the heel pad is disposed, or the peripheral portion of the mat is overlocked. It can be laminated and integrated by processing, tape processing or fusion processing, and manufactured in the same manner as described above.

  In the present invention, “bendable” means that the stress when a force is applied from the front-rear direction of the automobile or from the front-rear direction of the right is 6 N / 192 mm width, measured in the same manner as in the (evaluation of flexibility) example. This means that the smaller this stress is, the easier it is to bend. Therefore, it is preferably 5 N / 192 mm width or less, more preferably 4 N / 192 mm width or less, and 3 N / Most preferably, the width is 192 mm or less.

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

Example 1
(Skin layer)
Tufted carpet (== polypropylene cut pile, basis weight: 110 g / m ² ) tufted with polypropylene cut pile at a density of 1/8 gauge and stitch 11.3, then backed with styrene-butadiene rubber (= Skin layer, pile basis weight: 700 g / m ² , backing amount: 240 g / m ² ).

(Backing layer)
It consists of a polyester fiber having a fineness of 17 dtex, a polyester fiber having a fineness of 6.6 dtex, a polyester fiber having a fineness of 3.3 dtex, and a core-sheath type fusion fiber having a fineness of 4.4 dtex (core component: polyethylene terephthalate, sheath component: low-melting polyester). The fiber web was entangled using a needle, and then the fiber was protruded using a needle whose needle depth was increased to produce a needle punched nonwoven fabric in which the fiber protruded on one surface.

Next, heat treatment is performed at a temperature of 150 to 160 ° C. so that the sheath component of the core-sheath type fusion fiber is fused, and then the protruding fiber is heat-treated in a direct flame with a gas hair roasting machine to have a resin soul. A baked non-woven fabric (= backing material layer, basis weight: 300 g / m ² ) was produced.

(Precursor mat)
After the skin layer and the backing layer were bonded with a polyolefin hot melt adhesive (150 g / m ² ), the outer peripheral edge was cut into a convex shape as shown in FIG. 1 to form a precursor mat. The tufted carpet as the skin layer was bonded to the backing layer so that the gauge direction GD was parallel to the longitudinal direction L (front-rear direction Zd) of the automobile. The dimensions of the precursor mat were a = about 190 mm, b = h = about 120 mm, c = about 120 mm, d = f = about 640 mm, e = about 430 mm, and g = about 120 mm in FIG. In addition, the wrinkle movement area HA in the precursor mat is parallel to the g side in FIG. 1 and is parallel to the straight line Lf and the f side that are separated by 30 mm from the g side in the rear direction RD of the automobile, and from the f side to the front direction of the automobile. Straight line Lr separated by 105 mm in the left direction, parallel to straight line Lr, and straight line Ll separated from straight line Lr by 192 mm in the left direction of the automobile with respect to the forward direction of the automobile, and parallel to straight line Lf and straight line Lf A rectangular region of 112 mm in the longitudinal direction L of the automobile and 192 mm in the width direction W of the automobile, surrounded by a straight line Lb spaced by 112 mm in the rearward direction RD of the automobile.

(Heel pad)
A tufted carpet (pile weight), which is made of a polyester fiber primary base fabric (weight per unit: 120 g / m ² ), nylon tufted at a density of 1/10 gauge and stitch 10.0 and then backed with styrene-butadiene rubber. : 610 g / m ² , backing amount: 150 g / m ² ). The backing side was further backed with polyethylene resin (amount: 270 g / m ² ) to form a precursor heel pad. Next, the precursor heel pad was cut into a substantially rectangular shape to prepare a heel pad (short side length: 51.25 mm, long side length: 90.35, rounded to R7).

(mat)
The four heel pads were arranged in a lattice pattern of 2 rows and 2 columns in the heel movement area HA of the precursor mat. The heel pad HP ₁₁ in the first row and the first column and the heel pad HP _{21 in} the second row and the first column are spaced by 5 stitches (11.3 mm) and the heel pad HP ₁₁ in the first row and the first column and the first row. The heel pad HP _{12 in} the second row is spaced by 3 gauge (9.5 mm), and the heel pad HP ₂₂ in the second row and second column and the heel pad HP _{21 in} the second row and first column are 3 gauge (9. 9 mm). The heel pad HP _{22 in the} second row and the second column and the heel pad HP _{12 in} the first row and the second column are arranged with an interval of 5 stitches (11.3 mm). Each heel pad was arranged so that the short side direction was parallel to the length direction L of the automobile.

Thereafter, the heel pads HP _{11 to} HP ₂₂ were fixed by welding a polyethylene resin of the heel pad with a high frequency welder to manufacture the mat of the present invention.

(Comparative Example 1)
The precursor heel pad manufactured in the same manner as in Example 1 was cut into a substantially rectangular shape to produce a heel pad (short side length: 112 mm, long side length: 192 mm, rounded to R7). A mat was manufactured in the same manner as in Example 1 except that one heel pad was placed in the wrinkle movement region of the precursor mat.

(Reference Example 1)
Four heel pads manufactured in the same manner as in Example 1 were arranged in a lattice pattern of 2 rows and 2 columns in the heel movement area HA of the precursor mat. The heel pad HP ₁₁ in the first row and the first column and the heel pad HP _{21 in} the second row and the first column are spaced by 5 stitches (11.3 mm) and the heel pad HP ₁₁ in the first row and the first column and the first row. The heel pad HP _{12 in} the second row is spaced by 5 gauge (15.9 mm), and the heel pad HP ₂₂ in the second row and second column and the heel pad HP _{21 in} the second row and first column are 5 gauge (15.15 mm). The heel pad HP _{22 in the} second row and the second column and the heel pad HP _{12 in} the first row and the second column are arranged with an interval of 5 stitches (11.3 mm). In addition, each heel pad was arrange | positioned so that a short side direction might be parallel to the length direction L of a motor vehicle.

Thereafter, the heel pads HP _{11 to} HP ₂₂ were fixed by welding the polyethylene resin of the heel pads with a high-frequency welder to manufacture a mat.

(Reference Example 2)
Four heel pads manufactured in the same manner as in Example 1 were arranged in a lattice pattern of 2 rows and 2 columns in the heel movement area HA of the precursor mat. The heel pad HP ₁₁ in the first row and the first column and the heel pad HP _{21 in} the second row and the first column are spaced by 8 stitches (18.0 mm), and the heel pad HP ₁₁ in the first row and the first column and the first row. The heel pad HP _{12 in} the second row is spaced by 3 gauge (9.5 mm), and the heel pad HP ₂₂ in the second row and second column and the heel pad HP _{21 in} the second row and first column are 3 gauge (9. 9 mm). The heel pad HP _{22 in the} second row and the second column and the heel pad HP _{12 in} the first row and the second column were arranged with an interval of 8 stitches (18.0 mm). In addition, each heel pad was arrange | positioned so that a short side direction might be parallel to the length direction L of a motor vehicle.

Thereafter, the heel pads HP _{11 to} HP ₂₂ were fixed by welding the polyethylene resin of the heel pads with a high-frequency welder to manufacture a mat.

(Example 2)
The precursor heel pad manufactured in the same manner as in Example 1 was cut to prepare a triangular heel pad HP ₁ and a trapezoidal heel pad HP ₂ as shown in FIG. Except that these two heel pads HP ₁ and HP ₂ are arranged in the heel movement area of the precursor mat as shown in FIG. 5A (the distance between the heel pad HP ₁ and the heel pad HP ₂ is 5 mm). A mat was manufactured in the same manner as in Example 1.

(Example 3)
The precursor heel pad manufactured in the same manner as in Example 1 was cut to prepare two triangular heel pads HP ₁ and HP ₂ as shown in FIG. Except that these two heel pads HP ₁ and HP ₂ are arranged in the heel movement area of the precursor mat as shown in FIG. 5B (the distance between the heel pad HP ₁ and the heel pad HP ₂ is 5 mm). A mat was manufactured in the same manner as in Example 1.

Example 4
The precursor heel pad manufactured in the same manner as in Example 1 is cut into two triangular heel pads HP ₁ and HP ₄ as shown in FIG. 11C and trapezoidal heel pads HP ₂ and HP ₃ . Produced. These _four heel pads HP _{1 to} HP ₄ are arranged in the heel movement region of the precursor mat as shown in FIG. 5E (the distance between the heel pad HP ₁ and the heel pad HP ₂ is 5 mm, the heel pad HP. ₂ and the heel pad HP ₃ was 5 mm, and the heel pad HP ₃ and the heel pad HP ₄ were 5 mm apart from each other.

(Evaluation of flexibility)
The mats of Examples 1 to 4 and Reference Examples 1 and 2 were cut into a rectangular shape along the outer peripheral edge of the heel pad as shown in the top view of the test piece in FIG. Further, the mat of Comparative Example 1 was cut into a rectangular shape along the outer peripheral edge of the heel pad HP. Then, (1) a through-hole Hl having a diameter of 10 mm centering on the intersection of a straight line that bisects the long side and a long side that is 10 mm away from one long side and (2) two short sides From a through hole Hw having a diameter of 10 mm centering on the intersection of a straight line equally divided and a straight line parallel to the short side separated by 10 mm from one short side, or (3) From either the long side or the short side at the corner In addition, through holes Hc having a diameter of 10 mm centering on a point separated by 10 mm were formed and used as test pieces S, respectively.

  Next, as shown in a conceptual diagram in FIG. 4, when the through hole Hl is formed in the test piece S, a region separated from the through hole Hl in a direction parallel to the short side by a distance of 75 mm from the through hole Hl. In addition, a jig J having holes at both ends was placed, and a test piece S was fixed with a screw N (fixed width: 192 mm) through the holes of the jig. Further, when the through hole Hw is formed in the test piece S, a jig J having holes formed at both ends in a region separated from the through hole Hw in a direction parallel to the long side by a distance of 75 mm from the through hole Hw. And the test piece S was fixed with a screw N (fixed width: 112 mm) through a hole in the jig. Further, when the through hole Hc is formed in the test piece S, a jig J having holes formed at both ends in a region away from the point separated from the through hole Hc by 75 mm in the direction parallel to the short side from the through hole Hc. The test piece S was fixed with a screw N through the hole of the jig (fixed width: 192 mm).

In the fixed state, the hook F attached to the chuck of the tensile strength tester T is inserted into the through hole Hl, the through hole Hw, or the through hole Hc of the test piece S, and the test piece S is perpendicular to the test piece S. 500 mm / min. The stress was measured when the chuck was raised by 30 mm by pulling at a speed of. This stress was measured five times for each of the through hole Hl, the through hole Hw, or the through hole Hc, and the arithmetic average value was calculated. In the case of the through hole Hw, since the fixed width was 112 mm, the fixed width was converted to 192 mm. The results are shown in Table 1.

(Abrasion resistance evaluation method)
From the mats of Examples 1 to 4 and Reference Examples 1 to 2, a test piece S was prepared by cutting into a rectangular shape along the outer peripheral edge of the heel pad as shown in the top view of the test piece in FIG. Further, a test piece S was prepared by cutting the mat of Comparative Example 1 into a rectangular shape along the outer peripheral edge of the heel pad HP.

Next, each test piece S was worn under the following conditions using a Taber type wear tester specified in JIS L 1021-11, and then the surface condition was visually confirmed. The results are shown in Table 2.
Wear wheel: H-18
Load: 1000kgf
Rotation speed: 1000 times Rotation speed: 70 rpm

  From the comparison between Example 1 and Comparative Example 1 described above, by arranging two or more heel pads smaller than the wrinkle movement area in the wrinkle movement area of the skin layer, the flexibility in the longitudinal direction Zd of the automobile is improved. I found it excellent.

  In addition, from comparison between Example 1 and Reference Example 1, when the heel pads adjacent in the gauge direction of the pile are separated by a distance of 3 gauge or less, the wear resistance is excellent and the skin layer is protected. It turns out that it is excellent in function. Furthermore, from comparison between Example 1 and Reference Example 2, when the heel pads adjacent in the pile stitch direction are separated by a distance of 5 stitches or less, the wear resistance is excellent and the skin layer is protected. It turns out that it is excellent in function.

  Further, from the comparison between Example 1 and Examples 2 to 4, if there is a region that can be bent in a direction perpendicular to the longitudinal direction of the automobile, it is easily bent by the force from the longitudinal direction Zd of the automobile. It has been found that when a bendable region extending diagonally downward to the right with respect to the direction is provided, the vehicle can be easily bent by the force from the diagonally forward and backward direction Md of the automobile. Therefore, the mat of Example 1 is effective when it is easily caught on the brake pedal, and the mats of Examples 2 to 4 are effective when easily caught on the accelerator pedal.

  Further, from comparison between Examples 2 and 3 and Example 4, it was found that bending can be performed more easily by increasing the number of heel pads.

M mat HP, HP _nm heel pad HA 踵 Movement area L Length direction of automobile W Width direction of automobile FD Forward direction of automobile RD Rear direction of automobile GD Gauge direction SD Stitch direction Lf, Ll, Lb, Lr をthe length of the periphery of the straight a~h mat shown Hl, Hw, Hc through holes S specimen T tensile direction perpendicular J jig for strength tester U test piece N screw F hook Th _1, ·· Th ₈ holes (bent portion )
i ₁ , i ₂ , i ₃ Thin part (bent part)
Co ₁ ,... Co ₈ , Co ₁₁ ,... Co ₈₂ connection portion Zd longitudinal direction of automobile Md obliquely longitudinal direction of automobile

Claims (1)

A floor mat for an automobile having a skin layer made of carpet, and a flexible bending portion formed by arranging two or more heel pads smaller than the heel movement region in the heel movement region of the skin layer, or heel movement A heel pad having an incompletely separated bent portion is arranged in two or more regions smaller than the region, and the heel movement region is from the front-rear direction of the vehicle or the diagonally right-back direction of the vehicle when laying the floor mat for the vehicle. A floor mat for an automobile, which can be bent by the force of

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