JP6390448B2 - Floor mat and manufacturing method thereof - Google Patents

Description

  The present invention relates to a floor mat and a manufacturing method thereof. More specifically, the present invention relates to a floor mat having a raised surface made of napped fibers and a method for producing the same.

For a floor mat having a raised surface, a pile cloth or the like in which napped fibers (pile yarn or the like) are tufted on a base cloth is used. The pile cloth or the like is trimmed as necessary, and then subjected to terminal processing and decoration. As the above terminal treatment, a treatment for preventing the pile yarn exposed at the end portion of the pile cloth from falling off by trimming is performed. Specifically, an edge-edge process called overlock is performed. This is a process in which the trimmed end portion of the pile cloth is stitched over the entire circumference, and the pile yarn at the end portion is closed with the stitch yarn to cover it. Furthermore, the decoration is applied by embroidery.
The following patent document 1 and the following patent document 2 are known as techniques related to terminal processing of a floor mat having such a raised surface and decoration by embroidery.

JP 63-251342 A Japanese Utility Model Publication No. 04-054024

Patent Document 1 discloses a method of previously decorating a base cloth before embroidering a pile by embroidery, and then embedding the pile on the base cloth to obtain a mat having decoration on the raised surface. . However, this method cannot be applied to pre-tufted pile fabrics that are normally used, and there is a problem that terminal processing cannot be performed with this method.
On the other hand, in Patent Document 2, a trimming terminal is sewed with a sewing tape, and overlocking is performed so as to cover the sewing tape from above. However, in this method, although terminal processing by overlock can be performed, decoration by embroidery cannot be performed. That is, both terminal processing and decoration cannot be performed with one type of sewing machine. Further, when a terminal process is performed using an ordinary embroidery sewing machine (so-called pattern sewing machine), the napped fibers protrude from between the yarns. Therefore, the protruding of the napped fibers is prevented by the method of Patent Document 2. However, in the method of Patent Document 2 described above, no consideration is given to performing terminal processing using a normal sewing machine (so-called pattern sewing machine) that performs embroidery. Moreover, in the method of patent document 2, the process of sewing a sewing tape to a terminal will be needed, and the increase in a manufacturing man-hour will be caused.

  The present invention is an invention made in view of the above-described conventional situation, and provides a floor mat capable of performing both terminal processing and decoration only with a pattern sewing machine, and a method of manufacturing such a floor mat. With the goal.

In order to solve the above problem, the floor mat according to claim 1 is a floor mat having a raised surface formed by napped fibers erected on a base fabric,
In addition to having a saddle-shaped line formed in a saddle shape by embroidery on the surface as an edge treatment for the edge of the floor mat, it is also provided as a decoration formed in a portion other than the edge of the floor mat ,
The saddle type line includes the napped fibers, a resin film layer covering the napped fibers, and a yarn assembly layer covering the film layer in this order in the thickness direction,
Among these, the thread assembly layer is formed by lock stitching, and is formed by advancing embroidery in the longitudinal direction while reciprocating the thread in the width direction, and the thread assembly layer is interposed via the film layer. A gist is that the napped fibers are pressed down to the base fabric side by the inner surface of the film layer, and the film layer does not protrude outside the saddle line .
The gist of the floor mat according to claim 2 is that, in the floor mat according to claim 1 , the yarn assembly layer is formed only of the upper yarn.
The gist of the floor mat according to claim 3 is that, in the floor mat according to claim 1 or 2 , the yarn pitch in the longitudinal direction of the yarn assembly layer is 15 or less per cm.
Floor mat according to claim 4 is the floor mat according to any one of claims 1 to 3, the thickness of the film layer is summarized as 0.01~0.3mm der Rukoto.
In order to solve the above problem, [1] a floor mat is a floor mat having a raised surface formed by raised fibers erected on a base fabric,
It has a saddle-shaped line formed into a saddle shape by embroidery on the surface,
The saddle type line includes the napped fibers, a resin film layer covering the napped fibers, and a yarn assembly layer covering the film layer in this order in the thickness direction,
Of these, the yarn assembly layer is formed by advancing embroidery in the longitudinal direction while reciprocating the yarn in the width direction, and the film layer can be sewn to the base fabric with the yarn. .
[2] In the above [1], the floor mat may be subjected to edge processing on the edge of the floor mat by the saddle line.
[3] In the above [1] or [2], the [3] floor mat may have a decoration formed by the saddle type line in a portion other than the edge of the floor mat.
[4] In any one of the above [1] to [3], the [4] floor mat may be configured such that the yarn assembly layer is formed only of the upper yarn.
[5] In any one of the above [1] to [4], the [5] floor mat may have a yarn pitch in the longitudinal direction of the yarn assembly layer of 15 or less per 1 cm.
[6] In the floor mat according to any one of [1] to [5], the thread assembly layer may be formed by lock stitching.

In order to solve the above problem, the floor mat manufacturing method according to claim 5 is the floor mat manufacturing method according to any one of claims 1 to 4 ,
A film disposing step of disposing a resin film to be the film layer on the raised surface,
An embroidery step in which the thread assembly layer is formed by advancing embroidery in the longitudinal direction while reciprocating the thread in the width direction, and forming the saddle-shaped line by sewing the film to the base fabric;
And a removing step of removing an unnecessary portion of the film protruding outside the saddle type line.

  According to the floor mat of the present invention, only the pattern sewing machine can be used as a floor mat subjected to both terminal processing and decoration. Moreover, according to the manufacturing method of the floor mat of this invention, both a terminal process and decoration can be performed only with a pattern sewing machine.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
It is explanatory drawing explaining the planar shape of the surface of a floor mat. It is explanatory drawing explaining the cross-section of the principal part of an example of a floor mat. It is explanatory drawing explaining the cross-section of the principal part of the other example of a floor mat. It is explanatory drawing explaining the manufacturing method of a floor mat.

  The items shown here are for illustrative purposes and exemplary embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

[1] Floor mat The floor mat (1) has a raised surface (S ₁ ) formed by napped fibers (112) erected on the base fabric (111).
This floor mat (1) is provided with a saddle type line (13) formed in a saddle shape by embroidery on its surface (S ₁ ).
The saddle-shaped line (13) has a napped fiber (131), a resin film layer (132) covering the napped fiber (131), and a yarn assembly layer (133) covering the film layer (132). In this order in the vertical direction.
Of the napped fibers (131), the film layer (132), and the yarn assembly layer (133) included in the saddle line (13), the yarn assembly layer (133) is a yarn in the width direction (T ₁ ). Is formed by advancing embroidery in the longitudinal direction (T ₂ ) while reciprocating the film, and the film layer (132) is sewn to the base fabric (135, 111) with a thread (134). .

With this configuration, an excellent aesthetic line can be formed on the raised surface by the saddle line 13 while the yarn assembly layer 133 constitutes the outermost surface of the saddle line 13. The saddle type line 13 can be used as, for example, an edge processing line, a character of a decoration portion, a border, a pattern, or the like.
In addition, the saddle-shaped line 13 has a configuration in which the yarn collecting layer 133 is pressed against the base fabric 111 by the inner surface of the film layer 132 through the film layer 132. The napped fibers 131 are not exposed between the threads 134a of the corps 133.

That is, in general, when the napped fibers 131 are pressed against the base fabric 111 only by embroidery without using the film layer 132, it is necessary to narrow the space between the yarns 134a of the yarn assembly layer 133. However, in order to form the yarn assembly layer 133 by filling the space between the yarns 134a, it is necessary to reduce the pitch. Therefore, it takes time to form the yarn assembly layer 133, and the yarn length to be used becomes longer. There are disadvantages in terms of man-hours.
On the other hand, in this structure, the napped fibers 131 can be widely pressed down by the inner surface of the film layer 132, and the napped fibers 131 are not exposed from between the yarns even if the gaps between the yarns are not filled. Further, since the film layer 132 can be sewn to the base fabric 111 simultaneously with the formation of the yarn assembly layer 133, it is not necessary to sew the film layer 132 on the floor mat base material 1 'in advance, and can be manufactured efficiently. . In addition, since the film layer 132 is formed from a resin film, the film layer 132 is sewn to the base fabric 111 simultaneously with the formation of the yarn assembly layer 133. At that time, perforations are formed in dotted lines. Therefore, the unnecessary portion 20 of the film can be easily removed.

The above-described saddle type line 13 is a line formed in a saddle type. In other words, it can also be called a convex line. That is, it is a line that exhibits a ridge. The cross-sectional shape of the saddle-shaped line 13 is not particularly limited, and for example, it may be a substantially semicircular shape, a substantially semielliptical shape, a substantially square shape, a substantially rectangular shape, a substantially trapezoidal shape, or the like.
Further, brushed surface S ₁ of the floor mat 1 is flocked textile substrate 111 by tufting or the like and is formed by a napped fiber 112 which is erected. Examples of the napped fibers 112 include pile yarns. The tip of the surface S ₁ side of the napped fibers may be looped or may be cut.

Further, the width direction T ₁ and the longitudinal direction T ₂ described above correspond to the positions where the saddle type line 13 is formed. Specifically, in the ridge-type line 13, the width direction T ₁ direction along its width, the ridge-type line 13, along the direction in which the line is extended is a longitudinal T _2. And the width direction _{T 1} and a longitudinal _{T 2,} generally is crossed at substantially 90 degrees.

Further, the saddle type line 13 may be formed by any sewing method, but can be formed by the main sewing in particular. Further, the yarn assembly layer 133 can be formed only by the upper yarn. Furthermore, the thread pitch of the longitudinal _{T 2} in the yarn aggregate layer 133 may be a less than 15 lines per 1 cm, preferably to 10 to 15 present.
In addition, the type of yarn used for forming the yarn assembly layer 133 is not particularly limited, and an appropriate yarn can be used. For example, when the yarn material is nylon, polyethylene terephthalate, or polypropylene, 1000 to 2000 dtex is Preferably, 1500-1800 dtex is more preferable.

  The type of resin constituting the resin film layer 132 is not particularly limited, and may be a normal resin, a resin having an elastomeric property (rubber elasticity), or a thermoplastic resin. It may be a non-thermoplastic resin. Of these, thermoplastic resins are preferred. Specifically, olefin resins (polypropylene, polyethylene, mixed resins thereof, etc.), polyester resins (polyethylene terephthalate, etc.), polyamide resins (nylon 6, nylon 66, etc.), olefin thermoplastic elastomers, styrene heat Examples include plastic elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, and the like. These may use only 1 type and may use 2 or more types together.

In the floor mat 1, the edge processing for the edge 151 can be performed by the saddle type line 13A (see FIG. 2). That is, the vertical line 13 (13A) can be provided on the end edge 151 of the floor mat 1.
That is, conventionally, the processing at the edge 151 is performed using an overlock sewing machine, and the embroidery at the other portion 152 is performed using a pattern sewing machine, and it is necessary to use different sewing machines depending on the part to be processed on the floor mat. was there.
In contrast, in the present floor mat 1, the edge processing can be performed by embroidery through the film layer 132. That is, by forming the saddle-shaped line 13 (13A) on the end edge 151, it is possible to stop the napped fibers 112 from dropping off from the outer periphery of the floor mat 1 or unraveling the base cloth 111. .

Further, the saddle type line 13A formed on the end edge 151 can be formed by embroidery using a normal pattern sewing machine. That is, in the present floor mat 1, all parts can be formed by only one type of pattern sewing machine because both the processing of the edge 151 and the embroidery at other parts 152 can be formed by embroidery.
As the vertical line 13A by such edge processing, as shown in FIG. 1, an edge processing portion formed along the outer periphery of the floor mat 1 can be mentioned. The vertical line 13A in this case is arranged so as to surround the outer periphery of the floor mat 1. Then, it is possible to clarify the boundary between the floor mat 1 and the lower layer of the floor mat 1 (for example, a floor carpet layer in a vehicle cabin, a flooring or a carpet in a building, etc.) to give a design to the design. Moreover, the edge process part which edge-processed the inner periphery of the through-hole provided in the floor mat is mentioned. Specifically, a saddle-shaped line 13 </ b> A that is an edge processing portion on the inner periphery of the eyelet portion 153 is exemplified.

The part 152 other than the edge 151 of the floor mat 1 can have a decoration formed by the saddle-shaped line 13B (see FIG. 3). Only one of the above-described saddle type line 13A and the below-described saddle type line 13B may be formed on one floor mat 1, or both of them may be formed.
Unlike the edge processing, the saddle type line 13B is a line formed by embroidery in a portion 152 other than the edge of the floor mat base material 1 ′. The ridge-type line 13B is formed by advancing the embroidery longitudinally T ₂ while reciprocating the yarn in the width direction T _1. Specifically, it is used as a line for decorating the raised surface S ₁ of the floor mat 1. That is, for example, embroidery characters, embroidery borders, embroidery patterns, and the like can be mentioned. These may use only 1 type and may use 2 or more types together.

More specifically, as the parts that can be formed by the saddle type line 13B, when the floor mat 1 is a floor mat for vehicle interior, an eyelet part 153, a decoration part 155, a heel pad (not shown), etc. Is mentioned. These may use only 1 type and may use 2 or more types together.
Among these, the eyelet part 153 is a part used for fixing the floor mat 1 at a predetermined position in the passenger compartment. The eyelet portion 153 includes a through hole 154 that engages a locking tool fixed on the vehicle interior side, and an edge that is the inner periphery of the through hole 154 is processed by an edge line 13A. When in use, a locking tool (not shown) protruding from the floor in the vehicle compartment is inserted into a through hole 154 formed in the center of the eyelet part 153, and the locking tool is inserted into the eyelet part. The floor mat 1 can be locked at a predetermined position in the passenger compartment by being hooked on the vehicle.

Further, also, the decorative portion 155 on the side of the surface S ₁ of the floor mat 1 _(design surface), by using a ridge-type line 15B is a portion subjected to decoration. Specifically, there are an edge 155a formed by the saddle type line 13B, and an embroidery character, an embroidery figure, an embroidery pattern (not shown) formed by the saddle type line 13B in the edge 155a.

  Further, the heel pad is a part that is formed in a position in front of the traveling direction of the vehicle interior floor mat laid on the driver's seat and touched by the right footpad. According to the heel pad, it is possible to prevent the napped fibers 112 of the floor mat 1 from being peeled off by sliding with the driver's heel. At the same time, it can function as a slip stopper for the driver's heel.

The floor mat 1 of the present invention may be formed only from a carpet provided with the base fabric 111 and the napped fibers 112, but may include other layers. Examples of the other layer include a non-slip layer for a floor mat such as a backing layer, a nonwoven fabric layer, and a urethane layer. These other layers are all laminated on the back surface S ₂ side.
These layers may be disposed on the entire back surface S ₂ of the floor mat 1, it may be disposed only in a part. This backing layer is a layer that exhibits a soundproofing function against sound from under the floor, a waterproofing function that prevents permeation of moisture or the like adhering to the occupant's feet into the back side of the floor mat 1, and the like. The backing layer can be formed from a thermoplastic elastomer, other resin, rubber, or the like.

  In general, the floor mat 1 is detachably laid, takes in sand particles and dirt attached to the soles of shoes and feet, and is used for the purpose of preventing damage to the floor and preventing dirt. For example, indoor floor mats are used by placing them directly on the floor surface. Further, the vehicle format is detachably laid on the floor carpet laid on the entire floor of the vehicle interior. The vehicle mat is used for the purpose of preventing wear and dirt on the floor carpet. In particular, sand particles and the like adhering to the shoe of the occupant can be taken in and the scattering of the sand particles outside the floor mat can be suppressed, and the sand particles and the like taken in the floor mat can be removed outside the vehicle as needed.

[2] Manufacturing method of floor mat The manufacturing method of the floor mat of the present invention is the manufacturing method of the above-described floor mat 1.
This manufacturing method is a method including at least a film arrangement step (R1), an embroidery step (R2), and a removal step (R3).
Of these, film placement step (R1) is, on the brushed surface _{(S 1),} a step of disposing a resin film comprising a film layer (132) (132 ').
In the embroidery step (R2), the thread (134) is reciprocated in the width direction (T ₁ ) and the embroidery is advanced in the longitudinal direction (T ₂ ) to form the thread assembly layer (133) and the film (132 ′ ) Is sewn to the base fabric (111) to form the hooked line (13).
Further, the removing step (R3) is a step of removing the unnecessary portion (15) of the film (132 ′) protruding outside the saddle line (13) (see FIG. 4).

Hereinafter, a floor mat for vehicle interior used by laying in a vehicle interior and a method for manufacturing the same will be described in more detail with reference to FIGS.
[1] Manufacture of floor mat (1) Trimming step A floor mat base material 1 ′ is prepared by trimming a tufting mat having a base fabric 111 thickness of 2 mm and a napped fiber (pile yarn) height of 10 to 20 mm. It was. The floor mat base material 1 ′ is provided with a through hole 154 for forming the eyelet portion 153 (see FIGS. 1 and 4).

(2) after the step of film placement step (1), 'Towards a napped surface S ₁ of the upper film 132 made of resin on the napped surface S _1' resulting floor mat base member 1 mounting the The laminated body in the placed state (laminated state) was set on the pattern sewing machine. The film 132 'is a polyethylene having a thickness of 0.01 to 0.3 mm, floor mat base member 1 to cover the whole surface of the hair raising surface _{S 1'} is disposed on (see FIG. 4).

(3) Embroidery step After the step (2), the pattern sewing machine was operated in accordance with the preset settings, and each saddle type line 15 was formed by embroidery (see FIG. 4).
Specifically, as shown in FIG. 1, the edge 151 on the outer periphery of the floor mat base material 1 ′ and the edge 151 on the inner periphery of the through hole 154 for forming the eyelet portion 153 are sequentially A mold line 13A was formed. At this time, in Kakutan'en 151, while reciprocating the yarn in the width direction T _1, it was promoted needle toward the longitudinal direction T ₂ (advanced embroidery). Furthermore, this embroidery was formed by main sewing, and the thread assembly layer 133 was formed only by the upper thread 134a. Simultaneously with the formation of the thread assembly layer 133, the film 132 ′ was sewn to the base fabric 111 of the floor mat base material 1 ′ by the upper thread 134a and the lower thread 134b. Further, the thread pitch of the longitudinal _{T 2} of the yarn assembly layer 133 in each of ridge-type line 15A was 12 per 1 cm.

Further, as shown in FIG. 1, a saddle-shaped line 13 </ b> B is formed as a decorative portion 155 in a portion 152 other than the edge of the center portion of the floor mat base material 1 ′. The saddle type line 13B has a border, and an embroidery character can be drawn in the border as required by the saddle type line 13B. In this case, like the even ridge-type line 13A ridge type line 13B, while reciprocating the yarn in the width direction T _1, it was promoted needle toward the longitudinal direction T ₂ (advanced embroidery). Furthermore, this embroidery was formed by main sewing, and the thread assembly layer 133 was formed only by the upper thread 134a. Simultaneously with the formation of the thread assembly layer 133, the film 132 ′ was sewn to the base fabric 111 of the floor mat base material 1 ′ by the upper thread 134a and the lower thread 134b. Further, the thread pitch of the longitudinal _{T 2} of the yarn assembly layer 133 in each of ridge-type line 15B was 12 per 1 cm.

(4) Removal Step After the step (3), the unnecessary portion 20 of the film 132 ′ that protrudes to the outside of the vertical lines 13 (13A and 13B) is removed to obtain the floor mat 1 (FIG. 4). reference).
When removing the unnecessary portion 20 described above, it was possible to easily remove the unnecessary portion 20 along the vertical lines 13 by grasping and pulling the unnecessary portion 20. This is because, when the above-described yarn assembly layer 133 is formed, the perforation needles are penetrated through the film 132 ′ and perforations are formed in the film 132 ′ along each saddle type line 13. That is, when the unnecessary portion 20 is pulled, it can be easily and neatly removed by tearing along the perforation.

(5) Effects of Example The floor mat 1 obtained up to the above (4) was able to constitute all necessary parts only by embroidery. Furthermore, although each saddle type line 13 was formed by a general pattern sewing machine, no protrusion of pile yarn from between yarns of the yarn assembly layer 133 was observed.

Note that the present invention is not limited to those described in the specific embodiments described above, and can be variously modified embodiments within the scope of the present invention depending on the purpose and application.
That is, the floor mat 1 can be provided with other known layers such as a nonwoven fabric layer and a backing layer on the back surface S ₂ side as necessary. When these other layers are provided, before performing the above trimming process, necessary other layers are laminated on the back surface of the tufting mat before trimming, and these other layers are combined with the tufting mat in the trimming process. Trimming is preferred.

In the above embodiment, a floor mat having both the saddle type lines 15A provided on the end edge 151 and the vertical line 15B provided on the portion 152 other than the end edge 151 is obtained. However, only one of these can be formed.
That is, for example, after providing a saddle-shaped line 15A as an edge treatment for the edge 151, for example, a resin name plate can be welded to a necessary portion and replaced with the decoration portion 155. Moreover, after providing the bowl-shaped line 15B as the decoration part 155, an edge can also be processed by the conventional well-known method, for example.

  The foregoing description is for illustrative purposes only and is not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than restrictive. As detailed herein, modifications may be made in the embodiments within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials, and embodiments have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

1; floor mat, 1 ′; floor mat substrate, S ₁ ; surface, S ₂ ; back surface,
111; base fabric, 112; raised fiber,
13; vertical line, 13A; vertical line (a vertical line at the end edge 151), 13B; vertical line (a vertical line at the portion 152 other than the end edge), T ₁ ; width direction, T ₂ ; longitudinal direction ,
131; Napped fibers (napped fibers arranged in a saddle type line), 132; Film layer, 132 '; Resin film, 133; Yarn collecting layer, 134; Yarn (yarn constituting the yarn collecting layer), 134a Upper thread, 134b; lower thread, 135; base fabric,
151; edge,
152; parts other than the edge,
153; Eyelet part, 154; Through hole, 155; Decoration part, 155a;
20; unnecessary part of the film,
R1; film placement step,
R2: Embroidery process,
R3: removal step.

Claims (5)

A floor mat having a raised surface formed by raised fibers erected on a base fabric,
In addition to having a saddle-shaped line formed in a saddle shape by embroidery on the surface as an edge treatment for the edge of the floor mat, it is also provided as a decoration formed in a portion other than the edge of the floor mat ,
The saddle type line includes the napped fibers, a resin film layer covering the napped fibers, and a yarn assembly layer covering the film layer in this order in the thickness direction,
Among these, the thread assembly layer is formed by lock stitching, and is formed by advancing embroidery in the longitudinal direction while reciprocating the thread in the width direction, and the thread assembly layer is interposed via the film layer. The floor mat has a configuration in which the napped fibers are pressed to the base fabric side by an inner surface of the film layer, and the film layer does not protrude outside the saddle line .   The floor mat according to claim 1, wherein the yarn assembly layer is formed only by upper yarns. The floor mat according to claim 1 or 2 , wherein the yarn pitch in the longitudinal direction of the yarn assembly layer is 15 or less per 1 cm. The floor mat according to any one of claims 1 to 3, wherein the film layer has a thickness of 0.01 to 0.3 mm. A method for manufacturing a floor mat according to any one of claims 1 to 4 ,
A film disposing step of disposing a resin film to be the film layer on the raised surface,
An embroidery step in which the thread assembly layer is formed by advancing embroidery in the longitudinal direction while reciprocating the thread in the width direction, and forming the saddle-shaped line by sewing the film to the base fabric;
And a removing step of removing an unnecessary portion of the film that protrudes outside the saddle type line.

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