JPH10109582A - Floor mat for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicle floor mat that is lighter in weight, excellent in formability and made of materials thoughtfully considered to an issue of environmental quality without impairing washability. SOLUTION: A layered product, consisting of a surface layer 1 composed of a TPO (olefinic elastomer) or soft PP(polyprophylene) sheet, an intermediate layer 3 composed of a nonwoven fabric by a PET(polyethylene terephthalate) or another nonwoven fabric by mixing of this PET fabric and a polypropylene fabric, and a back layer 2 composed of a polypropylene or polyethylene sheet, is molded and thereby a floor mat is constituted, while since an end face of the intermediate layer 3 is sealed up, the surface quality and moldability of this floor mat are raised high, while any possible penetration of water into this intermediate layer 3 is prevented, and also washability is made so as to be secured. In addition, the floor mat has become disused is reused, capable of preventing the wastefulness of resources, or differently, even in the case where the disused mat is inevitably incinerated, undesirable chlorine gas is made so as not to be produced at all from the standpoint of environmental protection.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor mat for a vehicle, and more particularly, to a material that can be washed by water and has been given sufficient consideration to environmental problems.
The present invention relates to a vehicle floor mat which is lightweight and excellent in formability.

[0002]

2. Description of the Related Art Of the floor mats for vehicles, in particular, when constructing floor mats requiring water-washability, conventionally, as shown in FIG. 3, a surface layer 1 and a back layer made of virgin PVC (vinyl chloride resin) as shown in FIG. Recycled PVC between layers 2
In many cases, a laminated product sandwiching the intermediate layer 3 made of a mixture of virgin PVC and virgin PVC is used. In some cases, the intermediate layer 3 is formed as a foamed layer to enhance the grain transferability of the surface layer 1 during molding, or to enhance the texture of the floor mat.

[0003] However, PVC is poor in reusability, and when burning unnecessary floor mats, chlorine gas contained in PVC, which is a constituent material of the floor mats, is generated. There is a disadvantage that it is not preferable from a viewpoint.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and is a lightweight and excellent moldable vehicle made of a material that is environmentally friendly without impairing the water washability. It is an object to provide floor mats for use.

[0005]

SUMMARY OF THE INVENTION In order to solve the above problems, the present invention provides a nonwoven fabric or PET made of a surface layer composed of a sheet of TPO (olefin-based elastomer) or soft PP (polypropylene), and a PET (polyethylene terephthalate) fiber. A floor mat was formed by molding a laminate of an intermediate layer composed of a nonwoven fabric made of a blend of fibers and PP fibers and a back layer composed of a sheet of PP or PE (polyethylene), and the end face of the intermediate layer was sealed. It is characterized by:

[0006] The present invention also provides a method in which a laminate comprising a surface layer, an intermediate layer, and a back layer is formed by heating with a shear press, and the periphery of the laminate is cut off with a shear-cut blade to extend the surface layer along the end surface of the intermediate layer. Thus, the end face of the intermediate layer is sealed.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a cross-sectional view showing an embodiment of a vehicle floor mat according to the present invention, and FIG. 2 is a cross-sectional view illustrating a state in the process of forming the floor mat shown in FIG.

In these figures, the base material of the floor mat includes a surface layer 1 and a back layer 2, and is constituted by a laminated material in which an intermediate layer 3 is sandwiched between the surface layer 1 and the back layer 2 and these are integrated. ing.

Here, in the present embodiment, a sheet made of a soft thermoplastic resin material which is excellent in mold transferability like TPO or soft PP and which can satisfy surface quality such as texture is used. It constitutes the surface layer 1. The back layer 2 is formed of a sheet made of a soft thermoplastic resin material such as PP or PE, which is excellent in heat sealing performance and water tightness of a silencer (not shown).
The intermediate layer 3 sandwiched between the surface layer 1 and the back layer 2 having the above-described material configuration is formed of a nonwoven fabric of PET fibers or a nonwoven fabric of a blend of PET fibers and PP fibers.

As shown in FIG. 2, the base material formed of the laminate having the above-described structure is sandwiched between the upper die 5 and the lower die 6 of the shear press 4 and is heat-molded. The floor 7 is cut off with a blade 7 to obtain a floor mat having a predetermined shape. At the time of such forming, when the periphery is cut off by the shear cut blade 7 while the laminate is heated and formed by the shear press 4, the surface layer 1 softened by the forming heat is moved along the end surface of the intermediate layer 3 as the shear cut blade 7 descends. It is extended to form a seal portion 8, which seals the end face of the intermediate layer 3.

For this reason, the end face of the intermediate layer 3 can be sealed with the surface layer 1 without performing any special sealing work. Therefore, after molding, the surface and the end surface of the intermediate layer 3 are covered with the surface layer 1 and the back surface is covered with the back layer 2, so that the infiltration of water into the intermediate layer 3 made of nonwoven fabric is reliably prevented. Is done.

By the way, in the present invention, the surface layer 1 is TP
The back layer 2 is made of a sheet made of a soft thermoplastic resin material such as PP or PE, and the intermediate layer 3 is made of PET fiber while the back layer 2 is made of a sheet made of a soft thermoplastic resin material such as O or soft PP. Non-woven or PET
It is composed of a nonwoven fabric made of a blend of fibers and PP fibers. As described above, in the present invention, all of the surface layer 1, the back layer 2, and the intermediate layer 3 are made of a resin material containing no chlorine and having excellent reusability.

For this reason, it is possible to reuse unnecessary floor mats to eliminate waste of resources, or
Even if the floor mat is inevitably incinerated, there is no possibility of generating chlorine gas which is not preferable from the viewpoint of environmental protection.

Further, TPO or soft PP, which is a constituent material of the surface layer 1, has excellent mold transferability and good texture, so that a floor mat with high surface quality can be obtained. Further, PP or PE which is a constituent material of the back layer 2
Since the silencer (not shown) has excellent heat-sealing performance and water tightness, it is possible to enhance the bonding function of the silencer and the water tightness of the intermediate layer 3.

Further, since the intermediate layer 3 is formed of a nonwoven fabric of PET fibers or a nonwoven fabric of a blend of PET fibers and PP fibers, transferability of the molded grain to the surface layer 1 is reduced while reducing the weight of the intermediate layer 3. Therefore, the moldability can be improved.

That is, since the PET fiber constituting the mid layer 3 has high shape stability against warping, which is a concern at the time of molding, and is rich in flame retardancy, a floor mat for vehicles excellent in moldability and safety can be obtained. can get. In particular, when the intermediate layer 3 is formed of a nonwoven fabric made of a blend of PET fibers and PP fibers, the surface layer 1, the intermediate layer 3, and the back layer 2 are used during sheeting of the raw fabric.
Can be firmly bonded by a heat-sealing action of PP fibers which are a part of the constituent material of the intermediate layer 3.

When forming a laminate comprising the surface layer 1, the back layer 2, and the intermediate layer 3, vacuum forming can be used in combination. However, as shown in the above-described embodiment, the outer periphery is formed while being heat-formed by a shear press. Is cut off by the shear cut blade 7, the surface layer 1 softened by the forming heat is extended along the end face of the intermediate layer 3 as the shear cut blade 7 descends to form a seal portion 8, and the seal portion 8 is formed. However, since there is no need to provide a special sealing step for sealing the end face of the intermediate layer 3, there is an advantage that the production efficiency can be further increased.

[0018]

As is apparent from the above description, according to the present invention, all of the surface layer, the intermediate layer and the back layer of the floor mat are made of a chlorine-free resin material suitable for reuse. Therefore, the waste of the resources can be eliminated by reusing the unnecessary floor mats, or even if the floor mats are inevitably incinerated, chlorine gas which is not preferable from the viewpoint of environmental protection is not generated.

TPO or soft PP, which is a constituent material of the surface layer, is excellent in mold transferability and has good texture, so that a floor mat with high surface quality can be obtained. Alternatively, PE is excellent in the heat sealing performance and water tightness of the silencer, so that the adhesive function of the silencer and the water tightness of the intermediate layer can be enhanced.

Further, since the intermediate layer is made of a non-woven fabric of PET fiber or a non-woven fabric of a blend of PET fiber and PP fiber, it is possible to reduce the weight of the floor mat and secure the transferability of the molded grain to the surface layer. Even though it is possible, the end face of the intermediate layer that is not covered by the surface layer and the back layer is sealed, so that the infiltration of water into the intermediate layer can be reliably prevented. Can be secured.

Furthermore, the laminate comprising the surface layer, the back layer, and the intermediate layer is heat-formed by a shear press and the peripheral edge thereof is cut off by a shear-cut blade, thereby extending the surface layer along the end surface of the intermediate layer and sealing the end surface. In such a case, there is no need to provide a special sealing step, so that there is an advantage that the production efficiency of the floor mat can be further increased.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a vehicle floor mat according to the present invention.

FIG. 2 is a cross-sectional view illustrating a state in which the floor mat shown in FIG. 1 is being formed.

FIG. 3 is a sectional view showing an example of a conventional floor mat.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Surface layer 2 Back layer 3 Middle layer 4 Shea press 5 Upper die 6 Lower die 7 Shear cut blade 8 Seal part

Claims (2)

[Claims] 1. A surface layer composed of a sheet of TPO or soft PP, an intermediate layer composed of a nonwoven fabric of PET fibers or a nonwoven fabric of a mixture of PET fibers and PP fibers,
It is composed of a laminate of a back layer composed of a sheet of P or PE, and the molded body is molded into a predetermined shape,
A floor mat for vehicles, wherein an end face of an intermediate layer is sealed. 2. A laminate comprising a surface layer, an intermediate layer, and a back layer is formed by heating with a shear press while a peripheral edge of the laminate is cut off with a shear cut blade, thereby extending the surface layer along the end surface of the intermediate layer. The floor mat for a vehicle according to claim 1, wherein is sealed.