JP6413797B2 - Floor mat and manufacturing method thereof - Google Patents

Description

  The present invention relates to a floor mat and a manufacturing method thereof. More particularly, the present invention relates to a floor mat that is lightweight, easy to handle, and excellent in production efficiency, and a manufacturing method thereof.

Conventionally, a floor mat including a mat material made of a base fabric having napped fibers and a backing material that supports the mat material has been widely used (see, for example, Patent Document 1). And in this kind of floor mat, terminal treatment is desired from the viewpoints of protection of the peripheral portion (terminal) and designability.
The specific floor mat subjected to the terminal treatment includes, for example, (1) a mat material made of a base fabric having napped fibers, and a rubber nib backing layer disposed on the back surface and having a protrusion. The peripheral portion is sewn with an overlock sewing machine, (2) the mat material and a non-woven fabric layer disposed on the back surface thereof, and the peripheral portion is sewn with an overlock sewing machine. (3) The above mat material is provided with a urethane layer bonded to the back surface thereof and sliced on the outer surface side, and a peripheral tape such as cloth is sewn on the peripheral edge. It has been.

JP 2004-299576 A

However, when the above-described conventional terminal treatment is performed, in addition to the disposing step of disposing a backing layer, a urethane layer or the like on the back surface of the mat material, the overlock sewing machine is applied to the peripheral portion after the disposing step. Needless to say, a sewing process for performing sewing by sewing and sewing of an outer peripheral tape is necessary, and it is not yet sufficient in terms of production efficiency, and a reduction in the number of processes is required.
In addition, when a rubber nib backing layer is used as the backing material, the weight of the floor mat is increased, which is not sufficient from the viewpoint of handleability, is lighter, and has excellent handleability. It has been demanded.

  The present invention has been made in view of the above situation, and an object thereof is to provide a floor mat that is lightweight, easy to handle, and excellent in production efficiency, and a method for manufacturing the same.

In order to solve the above problem, an invention according to claim 1 is a floor mat comprising a mat material having a base fabric and napped fibers planted on the base fabric, and a backing material that supports the mat material. There,
The backing material is integrated with the back surface and the peripheral edge of the mat material, and is provided continuously with the backing portion disposed on the back surface of the base fabric and the backing portion, and the peripheral edge of the mat material. Comprising the napped fibers and the peripheral portion arranged to wrap the base fabric from the outer edge side, and made of a urethane material,
The peripheral portion covers and conceals the napped fibers at the peripheral edge of the mat material,
The tip of the peripheral edge is embedded between the napped fibers, and defines the napped fibers at the periphery and the napped fibers inside the tip.
The napped fibers at the periphery and the napped fibers inside the tip are continuously planted on the base fabric without interruption,
The gist of the invention is that the napped fibers at the peripheral edge and the napped fibers on the inner side of the tip end have the same height .
The gist of the invention of claim 2 is that, in the invention of claim 1, the backing material is integrally formed by injecting the urethane material to the mat material.
The gist of the invention described in claim 3 is that, in the invention described in claim 1 or 2, the outer surface of the backing portion of the backing material is subjected to a texture.
The gist of the invention described in claim 4 is that, in the invention described in any one of claims 1 to 3, it is used by being placed on the floor of a vehicle.
In order to solve the above problem, the invention according to claim 5 is a method for manufacturing a floor mat according to any one of claims 1 to 4,
A mounting step of mounting the mat material on a mold;
An integral molding step of injecting the urethane material into the mold and integrally molding the backing material on the back surface and peripheral edge of the mat material,
The mold includes one mold for mounting the mat material, and the other mold including a backing portion cavity that forms the backing portion,
The one mold is recessed so as to be opposed to the lining portion cavity, and a napped fiber accommodating portion that accommodates the napped fibers of the mat member, and is provided around the radially outer side of the napped fiber accommodating portion and the lining material. A peripheral cavity that forms the peripheral edge of
On the radially inner side from the peripheral part cavity, a peripheral support part is provided that protrudes to face the backing part cavity.
In the mounting step, at least an end portion of the mat material is supported by the peripheral edge support portion so that the peripheral edge and the back surface of the mat material are in contact with the urethane material injected into the mold.
Moreover, the end portion of the mat member is supported by the tip of the peripheral support portion being pierced into the base cloth,
The gist of the napped fibers at the peripheral edge of the mat member is arranged inside the peripheral cavity through the peripheral support portion.
The invention according to claim 6 is the invention according to claim 5 , wherein the peripheral edge support portion protrudes between the peripheral edge cavity and the napped fiber accommodating portion,
The inner peripheral surface of the peripheral edge support portion is provided to be continuous with the inner peripheral surface of the peripheral edge cavity,
In the integral molding step, the urethane material wraps around the back surface and the peripheral edge of the mat member, and on the inner peripheral surface of the peripheral cavity and the inner peripheral surface of the peripheral cavity on the inner peripheral side of the peripheral cavity. It is injected so that it may divide along between the said napped fibers along.

According to the floor mat of the present invention, the backing material is made of urethane, is light in weight, and is excellent in handleability during attachment and detachment. Further, since the backing material is integrally formed on the back surface and the peripheral edge of the mat material, the production efficiency is excellent.
In addition, when the outer surface of the lining portion of the lining material is subjected to a textured process, it is possible to further suppress slipping with respect to the floor mat placement surface.
According to the floor mat manufacturing method of the present invention, the formation of the backing material on the mat material and the terminal treatment at the peripheral edge of the mat material can be performed in one step. Therefore, the manufacturing can be simplified, the manufacturing time can be shortened, and the floor mat can be manufactured efficiently.

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 sectional drawing which illustrates the floor mat which concerns on an Example typically, (a) is a general view, (b) is an enlarged view of a peripheral part. It is a flowchart which shows the manufacturing method of the floor mat which concerns on an Example. It is sectional drawing which illustrates typically the lower mold | type which concerns on an Example. It is sectional drawing explaining typically the state which mounted | wore the lower mold with the mat material. It is sectional drawing which illustrates typically the state which installed the upper mold | type in the lower mold | type equipped with the mat material. It is sectional drawing which illustrates typically the state which injected the urethane material in the cavity of a metal mold | die.

  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.

The floor mat according to this embodiment includes a base material 12 and a mat material 10 having napped fibers 11 planted on the base fabric 12, and a backing material 20 that supports the mat material 10. The backing material 20 is integrated with the back surface and the periphery of the mat material 10, and is provided continuously with the backing portion 21 disposed on the back surface of the base fabric 12 and the backing portion 21. And a peripheral edge portion 22 arranged to wrap the base fabric 12 from the outer edge side, and the peripheral edge portion 22 includes the raised fiber 11 at the peripheral edge of the mat member 10. The tip portion of the peripheral edge portion 22 is embedded between the napped fibers 11, and defines the napped fibers 11 at the periphery and the napped fibers 11 inside the tip portion. The napped fibers 11 and the napped fibers 11 inside the tip are continuously planted on the base fabric 12 without interruption, and the napped fibers 11 on the inner side of the napped fibers 11 and the tip are in the periphery. Height is aligned and wherein the being (for example, see FIG. 1).

  The fiber material used for the mat material base fabric and napped fibers is not particularly limited, and can be appropriately selected from known materials.

  As a floor mat according to the present embodiment, for example, the backing material 20 can be integrally formed by injecting a urethane material onto the mat material 10.

  The urethane material is not particularly limited, and can be appropriately selected from known materials. In particular, it is preferable to use a material that is difficult to hydrolyze.

  As the floor mat according to the present embodiment, for example, the outer surface 20a of the lining portion 21 of the lining material 20 may have a textured shape. In this case, the slip with respect to the mounting surface of a floor mat can be suppressed more.

  In addition, as the floor mat according to the present embodiment, for example, at least the outer surface 20a of the backing portion 21 of the backing material 20 can be cured (see, for example, FIG. 1). In this case, waterproofness can be imparted to the floor mat. Furthermore, the surface becomes smooth and the design can be further improved.

  As the floor mat according to the present embodiment, for example, a form used by being placed on the floor surface of a vehicle such as an automobile can be cited. Specifically, it is laid on the floor of at least one of the driver's seat, passenger's seat, and rear seat in the passenger compartment of the automobile, and is laid on the floor of the cargo compartment of the automobile. May be.

The floor mat manufacturing method according to the present embodiment includes a mounting step (step S2) for mounting the mat material 10 on the molds 30 and 40, a urethane material is injected into the molds 30 and 40, the back surface of the mat material 10 and And an integral molding step (step S3) for integrally molding the backing material 20 on the periphery. In the mounting step (step S2), it is confirmed that at least the end portion of the mat material 10 is supported so that the peripheral edge portion and the back surface of the mat material 10 are in contact with the urethane material injected into the molds 30 and 40. Features (for example, see FIGS. 2 to 6).
In this case, the formation of the backing material on the mat material and the terminal treatment at the peripheral edge of the mat material can be performed in one step. Therefore, the production of the floor mat can be simplified, the production time can be shortened, and the floor mat can be produced efficiently.
In addition, it is not necessary to perform terminal processing by sewing with an overlock sewing machine or the like at the peripheral portion as in the past, and the design and design of the peripheral portion can be freely changed depending on the shape of the mold used for integral molding. can do.

  Hereinafter, the present invention will be specifically described with reference to the drawings. In addition, in a present Example, the floor mat used by mounting on the floor surface of vehicles, such as a motor vehicle, is illustrated.

(1) Configuration of Floor Mat As shown in FIG. 1 [(a) is an overall view, (b) is a partially enlarged view], the floor mat 1 according to the present embodiment has napped fibers 11 and a base fabric 12. A material 10 and a backing material 20 that supports the mat material 10 are provided. The mat member 10 is formed by implanting napped fibers 11 in a base fabric 12.

  The backing material 20 is made of a urethane material, is integrated with the back surface and the periphery of the mat material 10, and has a backing portion 21 and a peripheral portion 22. The urethane material can be appropriately colored by adding a pigment or the like. The thickness of the backing portion 21 is not particularly limited, but can be, for example, about 5 mm.

  The backing portion 21 is disposed on the back surface of the base fabric 12. The peripheral edge portion 22 is provided continuously with the backing portion 21 and is arranged so as to wrap the napped fibers 11 and the base fabric 12 at the peripheral edge of the mat member 10 from the outer edge side. The outer surface 20a of the backing material 20 is subjected to a hardening process and a texture process. The mat member 10 and the backing member 20 are integrally formed by injecting a urethane material onto the mat member 10.

(2) Action of Floor Mat Next, the action of the floor mat 1 having the above configuration will be described. When the floor mat 1 is placed on the floor of the vehicle, the back surface of the backing material 20 comes into contact with the floor of the vehicle. At this time, since the outer surface 20a of the backing material 20 is textured, slipping with respect to the floor of the vehicle is suppressed.

  Further, since the outer surface 20a of the backing material 20 is cured, for example, when wet shoes or the like are placed on the mat material 10, moisture that has entered from the mat material 10 side is transferred from the backing material 20 to the floor of the vehicle. Leaking to the side is suppressed. For this reason, the floor surface on which the floor mat 1 is placed is not contaminated with moisture, and the floor surface is protected even during rain.

  Moreover, since the outer surface 20a of the backing material 20 is cured, the surface becomes a smooth surface and the design is improved.

(3) Manufacturing method of floor mat Next, the manufacturing method of the floor mat 1 of the said structure is demonstrated along the flowchart shown in FIG. As described above, the floor mat 1 is integrally formed by injecting a urethane material onto the mat material 10.

  First, the lower mold 30 of the mold is prepared. As shown in FIG. 3, the lower mold 30 includes a peripheral cavity 31 for forming the peripheral edge 22 of the backing material 20, a napped fiber accommodating portion 32 that accommodates the napped fibers 11 of the mat material 10, and the mat material 10. A peripheral edge support portion 33 that supports the peripheral edge portion of the base fabric 12.

  The inner surface of the peripheral cavity 31 is, for example, mirror-finished so that the floor mat 1 after integral molding can be easily taken out. The peripheral edge support portion 33 protrudes upward between the peripheral edge cavity 31 and the napped fiber accommodating portion 32, and the tip thereof is lightly pierced into the base fabric 12 to prevent the movement of the base fabric 12 in the cavity. It has become.

  Then, as shown in FIG. 4, the mat member 10 is turned over and mounted on the lower mold 30 (step S <b> 1, mounting process). As a result, the peripheral edge portion of the base fabric 12 is supported by the peripheral edge support portion 33.

  Next, as shown in FIG. 5, the upper mold 40 is installed on the lower mold 30 (step S2). Here, as shown in FIG. 5, the upper mold 40 includes a peripheral cavity 41 for forming the peripheral edge 22 of the backing material 20, and a backing cavity 42 for forming the backing 21 of the backing 20. It has. The inner surfaces of the peripheral edge cavity 41 and the backing cavity 42 are mirror-finished, for example, so that the floor mat 1 after integral molding can be easily taken out. Further, fine irregularities are formed on the inner surface of the backing portion cavity 42, and the outer surface 20a of the backing portion 21 is subjected to a texture. The thickness of the backing portion cavity 42 is preferably 5 mm or more from the viewpoint of ease of distribution of the urethane material.

  Further, by combining the upper mold 40 and the lower mold 30, a gold that can be mounted on the mat material 10 by supporting at least the end portions of the mat material 10 so that the peripheral edge and the back surface of the mat material 10 are in contact with the urethane material. The mold can be configured.

  Next, as shown in FIG. 6, a urethane material is injected into the mold, and the urethane material wraps around the back side and the periphery of the mat member 10. Then, the cured urethane material is integrally formed on the back surface and the peripheral edge of the mat member 10 as the backing material 20 (step S3, integral molding step). At this time, the injection pressure of the urethane material is smaller than the injection pressure of the plastic, and the invasion to the mat material 10 is small. Therefore, deformation of the mat material 10 can be prevented. Further, the urethane material is integrated with the back surface of the base fabric 12 without passing through the base fabric 12. Since the urethane material in contact with the mold is cured, the outer surface 20a of the backing portion 20 is cured.

  Thereafter, the upper mold 40 is removed (step S4), and the floor mat 1 is removed from the lower mold 30 (step S5). Thereby, the floor mat 1 is formed.

(4) Effects of Example The floor mat 1 of the present example includes a backing material 20 made of a urethane material. The backing material 20 includes a backing portion 21 disposed on the back surface of the base fabric 12 and the backing material 20. A peripheral edge portion 22 provided continuously to the portion 21 and arranged so as to wrap the napped fibers 11 and the base fabric 12 at the peripheral edge of the mat member 10 from the outer edge side. As described above, since a lightweight, soft and low-cost urethane material is used, it is excellent in handleability at the time of attaching and detaching. In addition, it is possible to suppress deterioration in feeling of use and high cost. Furthermore, since the backing portion 21 and the peripheral portion 22 are integrally formed with the mat member 10, the production efficiency is excellent.
Further, in this embodiment, the outer surface 20a of the backing portion 21 of the backing material 20 is cured, so that the floor mat 1 can be easily removed from the integrally molded die. In addition, a release agent is not necessary, and cost can be reduced. And the surface becomes a smooth surface and can improve the designability. Furthermore, it is possible to suppress leakage of moisture that has entered from the mat material 10 side from the backing material 20. In particular, since the backing portion 21 and the peripheral portion 22 are integrally formed, the waterproof property can be improved.
Moreover, in the present embodiment, since the outer surface 20a of the backing portion 21 of the backing material 20 is textured, slipping with respect to the floor on which the floor mat 1 is placed can be sufficiently suppressed.

<Modification 1>
In the above-described embodiment, the inner surfaces of the peripheral cavity 31, the peripheral cavity 41, and the backing cavity 42 are all mirror-finished. However, the present invention is not limited to this. For example, Teflon (registered trademark) processing may be used, and in this case also, the floor mat 1 after integral molding can be easily taken out. Alternatively, depending on the shape of the floor mat 1, the surface treatment of the inner surface of the cavity can be made unnecessary.

<Modification 2>
In the embodiment described above, the outer surface 20a of the backing portion 21 is textured, but the present invention is not limited to this. For example, all the outer surfaces 20a of the backing material 21 may be subjected to a texture process. Alternatively, the outer surface 20a of the lining portion 21 may not be subjected to a texture process, and the hardened layer of the outer surface 20a of the lining portion 21 may be scraped off to use the difficulty of sliding the urethane material itself.

<Modification 3>
In the embodiment described above, the peripheral portion 22 of the backing material 20 is not subjected to the texture processing, but the peripheral portion 22 can be appropriately designed by designing the inner surface shape of the peripheral portion cavity 41.
The design and design can be freely changed.

  The foregoing examples are for illustrative purposes only and are 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 limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples 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.

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

  INDUSTRIAL APPLICABILITY The present invention is suitably used as a technique related to a floor mat that is used while being placed on a floor surface.

  DESCRIPTION OF SYMBOLS 1; Floor mat, 10; Mat material, 11: Napped fiber, 12: Base fabric, 20; Backing material, 20a; Outer surface, 21; Backing part, 22; Peripheral part, 30: Lower mold (mold), 40 Upper mold (mold).

Claims (6)

A floor mat comprising a base fabric and a mat material having napped fibers planted on the base fabric, and a backing material that supports the mat material,
The backing material is integrated with the back surface and the peripheral edge of the mat material, and is provided continuously with the backing portion disposed on the back surface of the base fabric and the backing portion, and the peripheral edge of the mat material. Comprising the napped fibers and the peripheral portion arranged to wrap the base fabric from the outer edge side, and made of a urethane material,
The peripheral portion covers and conceals the napped fibers at the peripheral edge of the mat material,
The tip of the peripheral edge is embedded between the napped fibers, and defines the napped fibers at the periphery and the napped fibers inside the tip.
The napped fibers at the periphery and the napped fibers inside the tip are continuously planted on the base fabric without interruption,
The floor mat, wherein the napped fibers at the peripheral edge and the napped fibers on the inner side of the tip end have the same height .   The floor mat according to claim 1, wherein the backing material is integrally formed by injecting the urethane material to the mat material.   The floor mat according to claim 1 or 2, wherein the outer surface of the lining portion of the lining material is subjected to a texture.   The floor mat according to any one of claims 1 to 3, wherein the floor mat is used by being placed on a floor surface of a vehicle. A method for manufacturing a floor mat according to any one of claims 1 to 4,
A mounting step of mounting the mat material on a mold;
Injecting the urethane material into the mold, and integrally forming the backing material on the back surface and the periphery of the mat material,
The mold includes one mold for mounting the mat material, and the other mold including a backing portion cavity that forms the backing portion,
The one mold is recessed so as to be opposed to the lining portion cavity, and a napped fiber accommodating portion that accommodates the napped fibers of the mat member, and is provided around the radially outer side of the napped fiber accommodating portion and the lining material. A peripheral cavity that forms the peripheral edge of
On the radially inner side from the peripheral part cavity, a peripheral support part is provided that protrudes to face the backing part cavity.
In the mounting step, at least an end portion of the mat material is supported by the peripheral edge support portion so that the peripheral edge and the back surface of the mat material are in contact with the urethane material injected into the mold.
Moreover, the end portion of the mat member is supported by the tip of the peripheral support portion being pierced into the base cloth,
The napped fibers at the periphery of the mat member are arranged inside the periphery cavity through the periphery support part, and the floor mat manufacturing method according to claim 1. The peripheral edge support portion protrudes between the peripheral edge cavity and the napped fiber accommodating portion,
The inner peripheral surface of the peripheral edge support portion is provided to be continuous with the inner peripheral surface of the peripheral edge cavity,
In the integral molding step, the urethane material wraps around the back surface and the peripheral edge of the mat member, and on the inner peripheral surface of the peripheral cavity and the inner peripheral surface of the peripheral cavity on the inner peripheral side of the peripheral cavity. The floor mat manufacturing method according to claim 5, wherein the floor mat is injected so as to be divided between the napped fibers along.

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