JPH1178645A - Floor mat and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor mat excellent in the tight attaching property with a floor wall, capable of preventing earth and sand from intruding to the floor and also excels in the design, and to offer a method of manufacturing the mat. SOLUTION: This floor mat is composed of a flat part 4 and peripheral edge part surrounding it, and at least part of the peripheral edge part includes a band-shaped bulge 5 extending continuously parallel with the peripheral edge 51 substantially, wherein the flat part side edge of the bulge 5 is substantially parallel with the peripheral edge, and the bulge 5 is provided at the undersurface with a groove which extends in the longitudinal direction of the bulge 5 and is in discontinuity in the longitudinal direction of the bulge 5, where a plurality of deformable nonlinear ribs 9 are furnished continuously on one side face of the groove, the bottom surface 66 of the groove, and the other side face 65a/65b of the groove.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a floor mat and a method for manufacturing the same. In particular, the present invention relates to a floor mat arranged around a floor mat in contact with a wall, for example, an automobile floor mat, or a floor mat for entrance to a store or home.

[0002]

2. Description of the Related Art For example, in a floor mat for an automobile, the floor is prevented from being stained,
In order to prevent soil, sand, mud, gravel, etc. from scattering to the outside of the floor mat, a floor mat with a band-shaped ridge on the periphery and a periphery higher than the central flat part is used. Are known. The most common method of manufacturing a floor mat of this type is a method of press-molding a sheet-like material. Therefore, the wall thickness of the central flat portion and the wall thickness of the peripheral band-shaped ridge are generally substantially the same. become. Therefore, a groove corresponding to the shape of the band-shaped ridge is formed on the lower surface side of the band-shaped ridge at the periphery. As described above, since the lower surface side of the band-shaped protruding portion has a groove-shaped hollow portion, when the band-shaped protruding portion is pressed with shoes or the like, or when the periphery is pressed against a wall surface, the band-shaped protruding portion is formed. However, there is a disadvantage that the floor mat is deformed, the position of the floor mat is displaced, and earth and sand enters under the floor mat.

In order to improve the shape stability of such a band-shaped ridge, Japanese Patent Application Laid-Open No. 6-24265 discloses that a linear rib portion traversing a hollow groove portion in a transverse direction (width direction) is provided inside the groove. Is disclosed. When this floor mat is pressed against a wall and a force is applied from the horizontal direction, the shape stability of the band-shaped ridge is enhanced, and the band-shaped ridge has no escape area for force. There was a problem that it easily occurred.

Further, a part of the band-shaped protruding portion is partially projected from the upper surface side of the floor mat toward the lower surface side, and discontinuous independent projections are periodically provided inside the groove-shaped formed portion. By doing so, it is conceivable to improve the shape stability of the band-shaped ridge. However, on the upper surface side of the projection, a dent in which a part of the band-shaped ridge is depressed toward the lower surface side is formed, and the smooth surface shape of the band-shaped ridge is impaired, so design In some cases, it gave an unnatural impression. Therefore, a solution from another viewpoint has been required.

[0005]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned drawbacks of the prior art, to have a proper shape retention property, and to install the apparatus in close contact with a wall surface in contact with the periphery of a floor mat. Floor mats which are less likely to be displaced, and which are less likely to penetrate under the floor mats, and which do not impair the smooth surface shape of the band-shaped ridges, and which are also excellent in design, and a method of manufacturing the same. Is to provide.

[0006]

According to the present invention, there is provided a flat part and a peripheral part surrounding the flat part, at least a part of the peripheral part being continuous substantially parallel to the peripheral part. A floor mat comprising a band-like ridge extending in the upper direction, wherein an edge of the band-like ridge on a flat portion side and a peripheral edge of the band-like ridge are substantially formed. Parallel; on the underside of said floor mat,
The ridge includes a groove extending the length of the ridge; wherein the groove is discontinuous in a length of the ridge, one side of the groove, a bottom surface of the groove, and the groove. A plurality of deformable non-linear ribs continuously provided on the other side of the floor mat. Further, the present invention is to send a sheet material maintained at a press-formable temperature to a pair of molds capable of press-molding a floor mat having the above-described shape, and press-mold the sheet by the mold, The present invention also relates to a method for manufacturing the floor mat, which is cut into individual floor mats.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a floor mat of the present invention will be described.
A description will be given mainly with reference to FIGS. 1 to 3 showing one embodiment. FIG. 1 is a perspective view of a floor mat 1 of the present invention as viewed from above, and FIG. 2 is an enlarged view of a corner 1a (broken line portion of FIG. 1) of the floor mat 1 as viewed from above. FIG. 3 is a partial perspective view, and FIG.
FIG. 4 is an enlarged partial perspective view of the front view from below. The floor mat 1 has a base layer 2 made of a molded elastic soft material sheet.
And a surface material layer 3 made of a carpet or the like. Further, a floor mat (not shown) consisting only of a formed elastic soft material sheet without carrying a surface material layer can also be used in the present invention. The underlayer 2 is preferably provided with anti-slip projections 21. As shown in FIG. 1, the floor mat 1 of the present invention includes a flat portion 4 at a central portion and a peripheral portion 4 a surrounding the flat portion 4.
Extends continuously along and substantially parallel to the periphery 51;
It includes a band-shaped ridge 5 protruding in the upper surface direction. Further, as shown in FIGS. 2 and 3, a groove 6 is formed on the lower surface of the floor mat 1 at a portion corresponding to the band-shaped ridge 5, that is, on the back side of the band-shaped ridge 5.

As shown in FIG. 1, on the upper surface of the floor mat 1 according to the present invention, an edge 5a of the band-shaped ridge 5 on the flat portion 4 side and an edge of the band-shaped ridge 5 on the peripheral edge 51 side. The edge 5b is substantially parallel. Floor mat 1
Generally, at least one side (typically the entire periphery) is used in contact with a wall surface, so that a corner portion may be arcuate (an arc shape having a center on the flat portion side) as shown in FIG. Other sides are substantially straight, except in some cases. Therefore, on the upper surface of the floor mat 1 according to the present invention, generally, the edge 5a on the flat portion 4 side of the strip-shaped protruding portion 5 is substantially composed of only a straight edge (corner portion). Form a corner), and a substantially straight side edge, and an arc-shaped edge of a corner centered on the flat portion side. That is, generally, the boundary between the flat portion 4 and the edge 5a on the flat portion 4 side of the band-shaped ridge 5 does not become a zigzag or wavy boundary.

On the upper surface side of the band-shaped protruding portion 5, not only a projection protruding from the upper surface side to the upper surface direction of the floor mat 1 is not provided, but also the reverse direction from the upper surface side surface to the lower surface direction of the floor mat 1. It is preferable not to form a depressed dent, and it is preferable that the upper surface side of the band-shaped ridge 5 is formed of a smooth surface. Further, the width and depth of the groove 6 formed on the lower surface side of the band-shaped protruding portion 5 are not particularly limited, but since the manufacturing process becomes easy, the entire wall of the band-shaped protruding portion 5 is formed. It is preferable to provide the groove 6 having a width and a depth such that the thickness is substantially the same except for a portion provided with a deformable non-linear rib 9 described later along FIG. In addition, in this specification, "the wall thickness of the strip | belt-shaped protruding part 5" means
When the floor mat of the present invention is composed of a laminate of a base layer and a surface material layer, it means the thickness of the base layer at the band-shaped ridges 5, and the floor mat of the present invention does not carry the surface material layer. In the case where only the molded sheet is used, it means the thickness of the molded sheet at the band-shaped ridge 5. In addition, since the manufacturing process is further facilitated, the entire wall thickness of the strip-shaped raised portion 5 is substantially equal to the wall thickness of the flat portion 4 except for the portion where the deformable non-linear rib 9 is provided. It is more preferable to provide a groove having a width and a depth substantially equal to each other.
However, the side wall 63 and the ceiling 6 on both sides of the band-shaped ridge 5
4, by making one or more wall thicknesses greater than the wall thickness of the flat portion 4, the function of retaining the shape of the band-like ridge 5 can also be improved.

The belt-like ridge 5 has a side wall 63 and a ceiling 64.
And a plurality of deformable non-linear ribs 9 in the groove 6. The deformable non-linear rib 9 is continuous from one side surface 65a of the groove 6 to the other side surface 65b of the groove 6 via a bottom surface (ceiling surface) 66 of the groove 6, but has a band-like ridge. The portions 5 are independent of each other in the length direction. In the present specification, the term "deformable non-linear rib" means a groove in the band-shaped ridge on the floor mat, which is discontinuous in the length direction of the band-shaped ridge, and a groove from one side surface of the groove. Through the bottom surface of the groove and the other side surface of the groove, and a projection section extending from one side surface to the other side surface of the groove (the lower surface of the flat portion of the floor mat). (A cross section parallel to), the center line does not consist of only one straight line, but means the protruding portion having a portion where the center line is curved and / or bent. The “curved” means that the center line is an arc-shaped curve, and a substantial portion of the rib is referred to as a curved portion.
The term “bent” means that the center line is formed by two straight lines, one straight line and one curved line, or two curved lines at a certain angle (1
(Excluding 80 degrees)
The intersection of one straight line, one straight line and one curved line, or two curved lines is called a bending point, and a portion corresponding to the bending point in the rib is called a bent portion. In the rib, a portion where the center line corresponds to a straight line is referred to as a straight portion. In the deformable non-linear rib of the present invention, one rib has at least one bent portion or at least one curved portion. That is, the deformable non-linear rib includes at least one curved portion or at least one bent portion.

A typical shape and arrangement of the deformable non-linear ribs 9 will be described with reference to FIGS. FIG.
FIG. 2 schematically shows the shape and arrangement of the deformable non-linear rib 9 shown in FIGS. That is, FIG.
Describes the arrangement of the deformable non-linear ribs 9 in the groove 6, the edge 67 of the groove 6 on the peripheral edge 51 side, and the edge 6 of the flat portion 4
FIG. 4B is a schematic bottom view as viewed from the lower surface of the floor mat 1 schematically showing only the deformable non-linear ribs 9 and the deformable non-linear ribs 9 therebetween.
FIG. 3 is a schematic cross-sectional view showing a cross section taken along the line bb of FIG. 5 to 12 below
Also, in each figure (a), the arrangement state of the deformable non-linear rib 9 in the groove 6 shows
It is a typical bottom view shown only by the edge 68 of the flat part 4 side, and the deformable non-linear rib 9 between them, and each figure (b) is bb line cross section of each figure (a). FIG. 3 is a schematic cross-sectional view showing a part of a flat part 4 continuing from the figure.

FIG. 4 shows an embodiment in which the deformable non-linear rib 9 is composed of two straight portions 91a and 91b and has one bent portion 92a. FIG. 5 shows that the deformable non-linear rib 9 includes four linear portions 91a to 91d,
Moreover, an embodiment having three bent portions 92a to 92c is shown. FIG. 6 shows that the deformable non-linear rib 9 is composed of nine straight portions 91a to 91i, and furthermore, has eight bent portions 9a.
An embodiment having 2a to 92h is shown.

FIG. 7 shows an embodiment in which the deformable non-linear rib 9 comprises one curved portion 93a. FIG. 8 shows an embodiment in which the deformable non-linear rib 9 is composed of two curved portions 93a and 93b curved in the same direction (with respect to the length direction of the groove 6), and has one bent portion 92a. . FIG.
The two deformable non-linear ribs 9 are curved in opposite directions (with respect to the length direction of the groove 6).
b shows an embodiment consisting of: 4 to 9, the deformable non-linear rib 9 is provided between the edge 67 of the groove 6 on the peripheral edge 51 side and the edge 68 of the groove 6 on the flat portion 4 side. ing.

FIG. 10 shows that the deformable non-linear rib 9 has one
An embodiment is shown in which one straight portion 91a and one curved portion 93a are provided, and one bent portion 92a is provided. FIG.
In the embodiment shown in FIG.
The two straight portions 91a and the one curved portion 93a are arranged in this order from the edge 68 on the flat portion 4 side of the groove 6 to the peripheral edge 51 of the groove 6.
In the floor mat 1 according to the present invention, one straight portion 91a and one curved portion 93a of the deformable non-linear rib 9 are provided in the direction of the side edge 67.
In this order, the groove 6 may be provided in the direction from the edge 67 on the peripheral edge 51 side to the edge 68 on the flat portion 4 side of the groove 6.

FIG. 11 shows that the deformable non-linear rib 9 has two ribs.
An embodiment is shown that includes two straight portions 91a and 91b and one curved portion 93a and has two bent portions 92a and 92b. In the embodiment shown in FIG. 11, the two straight portions 91a and 91b and one curved portion 93a of the deformable non-linear rib 9 are formed in this order from the edge 68 of the groove 6 on the flat portion 4 side to the groove 6 Are provided in the direction of the edge 67 on the side of the peripheral edge 51, but in the floor mat 1 according to the present invention, the two linear portions 91 in the deformable non-linear rib 9 are provided.
a, 91b and one curved portion 93a may be provided in this order from the edge 67 of the groove 6 on the peripheral edge 51 side to the edge 68 of the groove 6 on the flat portion 4 side.

In the embodiments of FIGS. 4 to 11, the lower surface 94 of the deformable non-linear rib 9 (that is, the bottom surface facing the floor surface when the floor mat 1 according to the present invention is laid on the floor surface) is formed. , Has reached the lower surface extension surface of the flat portion 4,
The lower surface may not reach the lower surface extension surface of the flat portion 4. FIG. 12 shows an example of the latter mode. FIG. 12 shows that the lower surface 94 of the deformable non-linear rib 9 is
There is no difference from the embodiment of FIG. 4 except that the groove 6 is located at a position raised toward the bottom surface (ceiling surface) 66 of the groove 6. 5 to 11, the lower surface 9 of the deformable non-linear rib 9 is also provided.
The deformable non-linear rib 9 can be provided so that the groove 4 is located at a position raised toward the bottom surface (ceiling surface) 66 of the groove 6. However, in this case, when a force is applied to the floor mat 1 placed on the floor surface and the groove-shaped ridge 5 is deformed, the lower surface side surface 94 of the deformable non-linear rib 9 comes into contact with the floor surface, It is preferable that the shape of the groove-shaped protrusion 5 can be maintained to a certain extent. The deformable non-linear rib 9
The lower surface 94 of the flat portion 4 can protrude further to the lower surface side than the extended surface of the lower surface of the flat portion 4. However, when the protrusion 21 exists on the lower surface of the flat portion 4, the effect of preventing the protrusion 21 from slipping is reduced. It is preferable that it protrudes to the extent that it does not decrease.

The lower surface 94 of the deformable non-linear rib 9 may be a flat surface, but may be an arc-shaped surface (an arc-shaped surface whose center is on the bottom surface of the groove carrying the deformable non-linear rib).
Alternatively, it may be an arc shape on the side opposite to the groove bottom side that carries the deformable non-linear rib. 4 to 1.
In FIG. 2, a description has been given of the floor mat having no surface layer made of a carpet or the like, but FIGS.
The description of 2 also applies to a laminated sheet type floor mat having a surface material layer as it is.

As is apparent from the above description, the "groove" in the floor mat according to the present invention is a depression formed in the strip-shaped protruding portion and composed of the ceiling portion and the side wall portion continuous therewith. When the entire interior of the groove is hollow without providing any deformable non-linear ribs inside, the wall thickness of the entire side wall portion and / or the entire ceiling portion is in the longitudinal direction of the band-shaped ridge. And / or substantially constant, continuously decreasing or continuously increasing depression in the width direction. Therefore, the cross-sectional shape of the groove 6 (the cross-sectional shape in the width direction of the groove) is not particularly limited, and for example, for example, a semicircle, a semi-ellipse, or a polygon [for example, a trapezoid (see FIGS. 2 to 12), a square, Rectangle or triangle having a long side or a short side as a ceiling portion], or a combination thereof.

It is to be noted that the groove in the present specification necessarily includes the “ceiling part” and the “side wall part”, and the “ceiling part” in the groove is defined as a lower surface of a flat part of a floor mat. The height (depth) from the extension surface indicates the maximum value, or the maximum value and a value corresponding thereto, and the “side wall portion” in the groove is continuous with the ceiling portion, Means a portion extending to the edge of When the cross-sectional shape of the groove is, for example, trapezoidal, square, or rectangular, a horizontal portion (corresponding to the upper side of the trapezoid, square, or rectangle) located substantially at the center of the groove (in the width direction of the groove) A portion (corresponding to a side in a trapezoid, square, or rectangle) continuous with the “ceiling portion” corresponds to the “side wall portion”. In addition, when the cross-sectional shape of the groove is, for example, a semicircular or semi-elliptical shape, a substantially horizontal portion located at a substantially central portion (in the width direction of the groove) of the groove corresponds to the “ceiling portion”. , A portion continuous therewith corresponds to the “side wall portion”. Further, when the cross-sectional shape of the groove is, for example, a triangle, the portion (corresponding to the apex in the triangle) where the height (depth) shows the maximum value and the vicinity located on both sides of the portion are the above-mentioned “ceiling”. Portion, and a portion continuous therewith corresponds to the aforementioned “side wall portion”.

In the floor mat according to the present invention, it is preferable that the deformable non-linear ribs of the same shape are periodically arranged at equal intervals, but the deformable non-linear ribs of different shapes are combined or different. It is also possible to combine deformable non-linear ribs having a different thickness, or to change the arrangement interval.

Since the deformable non-linear rib 9 provided on the band-shaped ridge 5 has a curved portion 93 and / or a bent portion 92, pressure is applied to the band-shaped ridge 5 from the direction of the flat portion 4 (FIG. 4). (Direction indicated by arrow B) acts, the deformable non-linear rib 9 itself deforms, thereby absorbing the force. The floor mat 1 of the present invention is generally used such that the peripheral edge 51 of the peripheral portion 4a is in close contact with the wall surface. Therefore, the floor mat 1 generally has a pressure in the direction of pushing against the wall surface (direction indicated by arrow B in FIG. 4) or the pressure in the direction of pulling from the wall surface (direction indicated by arrow C in FIG. 4). ) Works. For example, when pressure is applied to the belt-like ridge 5 from the direction of the flat part 4 in the pushing direction (the direction of arrow B), the deformable non-linear rib provided on the belt-like ridge 5 Since the force can be absorbed by the deformation of 9, the displacement can be effectively prevented. On the other hand, when pressure is applied to the belt-shaped ridge 5 in the direction of pulling in the direction of the flat portion 4 (the direction of arrow C), distortion due to the pressure is eliminated. Further, in the floor mat 1 according to the present invention, since the deformable non-linear ribs 9 connect both side surfaces 65a and 65b of the band-shaped ridge 5, a pressure is applied to the band-shaped ridge 5 from the vertical direction. As a result, the shape of the band-shaped ridge 5 can be maintained.

In the floor mat 1 of the present invention, the deformable non-linear rib 9 is provided in a shape in which a projection is carried on the inner wall surface of the hollow groove 6. That is, the protrusion is provided on the inner wall surface of the groove 6 in such a manner as not to affect the shape of the upper surface side of the band-shaped protrusion 5. Therefore, when observing from the upper surface side of the belt-shaped ridge 5, the position where the deformable non-linear rib 9 is provided and the position where the deformable non-linear rib 9 is not provided cannot be distinguished at least on the shape. Thus, the floor mat 1 according to the present invention can satisfy the design requirements for the floor mat.

In the floor mat 1 of the present invention, FIGS.
As shown in (1), it is preferable to provide the band-shaped ridge 5 on the entire periphery 4a. However, the band-shaped ridge 5 can be provided on at least a part of the periphery 4a. For example, a floor mat 1 [sides (a), (b), (c),
(D), (e) and (f)] is used as a floor mat for a driver's seat of an automobile when the pressure from the driver's feet is mainly in the traveling direction (the direction of arrow A in FIG. 1). Often joins. Therefore, when the band-shaped ridges 5 are provided on the sides (a) and (c), the displacement due to the pressure can be effectively prevented. In addition, when the band-shaped ridges 5 are provided on the sides (b), (d), and (f), it is possible to effectively prevent the displacement due to the pedaling force when getting on and off the driver's seat.

When the floor mat of the present invention comprises a laminate of a base layer and a surface layer, the floor mat comprises only a molded sheet as a molding material for the base layer or without carrying the surface layer. In such a case, the molding material may be a thermoplastic resin, for example, a thermoformable polyvinyl chloride, an ethylene-vinyl acetate copolymer, or polyethylene, as in the case of a conventional floor mat; a thermoplastic elastomer, for example, a styrene-based thermosetting resin. Thermoplastic elastomer, polyolefin-based thermoplastic elastomer, or polyvinyl chloride-based thermoplastic elastomer; thermosetting resin, for example, phenolic resin, polyurethane, or unsaturated polyester resin; or, natural rubber or synthetic rubber, for example, styrene-butadiene rubber , Butadiene rubber, isoprene rubber, or nitrile
It can be made of butadiene rubber or the like. The hardness (Shore A hardness) of the thermoformable material is preferably 50
~ 90, more preferably 65-80.

Among them, the thermoplastic elastomer is relatively soft and contributes to the adhesion to the floor wall, so that it can be suitably used. Further, the thermoplastic elastomer has advantages that it can be recycled, can be molded by a usual molding machine, has a short molding time, and can be continuously molded. Examples of the styrene-based thermoplastic elastomer include a polystyrene-polybutadiene-polystyrene (SBS) thermoplastic elastomer and a polystyrene-polyisoprene-polystyrene (SIS).
A thermoplastic elastomer can be used, and as the polyolefin-based thermoplastic elastomer, for example,
EPDM (ethylene-propylene-diene copolymer)
A blend of an olefin rubber such as an olefin rubber and an olefin resin such as a polypropylene, an alloy or a block copolymer can be used. Examples of the polyvinyl chloride elastomer include a blend of a nitrile rubber and a polyvinyl chloride. Can be suitably used. When a thermoplastic elastomer is used, a crosslinking treatment can be performed. Among these thermoplastic elastomers, olefin-based thermoplastic elastomers are lightweight,
Since it has excellent weather resistance, it can be suitably used.

When the floor mat of the present invention comprises a laminate of a base layer and a surface material layer, the surface material may be, for example,
A tufted carpet, a needle punch carpet, a woven fabric, or the like can be used.

The floor mat of the present invention can be manufactured by various methods. For example, when the molding material is a thermoplastic resin, the floor mat is manufactured by the following method shown in FIGS. Is preferred. That is, FIG.
As shown in FIG. 3, a thermoplastic elastomer sheet 13 is placed on a surface material carpet 12 (supplied from a supply roll not shown) conveyed on a belt conveyor 11a.
Is supplied from the extrusion molding nozzle 14. In addition, the thermoplastic elastomer sheet 13 can be directly supplied from the extrusion molding nozzle 14 onto the belt conveyor 11a, and the carpet 12 can be placed thereon and sent to the next step. continue,
The belt conveyor 1 is passed through a buffer 15 provided in some cases.
It is sent to the auxiliary heater 17 by 1b. In the auxiliary heater 17, the elastomer sheet 13 is heated to a temperature at which cold pressing is possible in the next pressing step. However, when the elastomer sheet 13 is conveyed while being maintained at the molding temperature, it is not necessary to heat the sheet with the auxiliary heater 17.

Subsequently, the laminate is conveyed to the cold press device 18 by the belt conveyor 11b, the belt conveyor 11b is temporarily stopped, and the pair of forming dies 18a and 18b are sequentially moved by the cold press device 18. The stack is moved up and down, and a flat portion 4, a band-like ridge 5 at a position corresponding to a peripheral portion 4 a surrounding the flat portion 4, and a deformable non-linear rib 9
And, if necessary, a non-slip projection 21 is formed on the surface of the flat portion 4 on the lower surface side, and at the same time, the carpet 12 and the elastomer sheet 13 are adhered. Next, the press-formed laminate is transported to the cutting device 19, and cut at the individual peripheral edges 51 to produce the floor mat 1 of the present invention, which can be transported by the belt conveyor 11c. The cold press device 18 may be provided with a cutting means, and the press forming step and the cutting step may be performed simultaneously. Further, it is preferable to synchronize the processing by the cold press device 18 and the cutting device 19 with the temporary stop of the belt conveyor 11b.
In addition, the said buffer part 15 is the said belt conveyor 11
a) generally continuous transport and belt conveyor 11b
It is preferably provided as a buffer for adjusting intermittent conveyance due to the above-mentioned method.

Alternatively, as shown in FIG. 14, a thermoplastic elastomer sheet 13 is supplied onto a belt conveyor 11a from an extrusion molding nozzle 14 and sent to an auxiliary heater 17 by the belt conveyor 11a. The carpet 12 (supplied from the supply roll 12a). In the auxiliary heater 17, the elastomer sheet 13
Is heated to a temperature at which cold pressing is possible in the next pressing step using the emboss rollers 20a and 20b. However, when the temperature of the elastomer sheet 13 is maintained at the molding temperature, there is no need to heat the sheet with the auxiliary heater 17. In the process shown in FIG.
An elastomer sheet 13 can be supplied from an extrusion nozzle 14 onto the carpet 12 conveyed on 1a.

Subsequently, it is sent to the embossing press device 20 by the belt conveyor 11a. In the embossing press device 20, the laminate is passed between the embossing rollers 20a and 20b, and a flat portion 4 and a band-like ridge 5 at a position corresponding to a peripheral portion 4a surrounding the flat portion 4 are formed on the laminate. The possible non-linear ribs 9 and, if appropriate, anti-slip projections 21 are formed on the lower surface side of the flat part 4, and the carpet 12 and the elastomer sheet 13 are simultaneously adhered. Next, the press-formed laminate is conveyed to the cutting device 19 by the belt conveyor 11c via the belt conveyor 11b and the buffering unit 15 provided in some cases, and the belt conveyor 11c is temporarily stopped, and the individual peripheral edges are stopped. The floor mat 1 of the present invention is manufactured by cutting at 51, and can be transported by the belt conveyor 11d. The buffer 15 is preferably provided as a buffer for adjusting generally continuous conveyance by the belt conveyors 11a and 11b and generally intermittent conveyance by the belt conveyor 11c.

Further, as shown in FIG. 15, the carpet 12 for the surface material and the thermoplastic elastomer sheet 13 are directly supplied to the embossing rollers 20a and 20b arranged in parallel from the supply roll 12a and the extrusion molding nozzle 14, respectively. It can also be supplied. In this case, since the elastomer sheet 13 is supplied at a temperature at which cold pressing by the embossing device 20 is possible, there is no need to provide an auxiliary heater. In the embossing press device 20, the laminate of the carpet 12 for the front material and the thermoplastic elastomer sheet 13 is passed between the embossing rollers 20a and 20b, and the flat portion 4 and the peripheral portion surrounding the flat portion 4 are passed through the laminate. At a position corresponding to 4a, a strip-shaped ridge 5, a deformable non-linear rib 9, and a non-slip projection 21 are formed on the surface of the flat portion 4 on the lower surface side.
And the elastomer sheet 13 are adhered. Next, the laminate formed by pressing is passed through the belt conveyor 11a and the buffer 15 provided if necessary, and then passed through the belt conveyor 11b.
, The belt conveyor 11b is temporarily stopped, and cut at each peripheral edge 51 to produce the floor mat 1 of the present invention, which can be conveyed by the belt conveyor 11c. The buffer 15 is preferably provided as a buffer for adjusting generally continuous conveyance by the belt conveyor 11a and generally intermittent conveyance by the belt conveyor 11b.

The case where the molding material is a thermoplastic resin has been described with reference to FIGS. 13 to 15 as an example of the method for manufacturing a floor mat according to the present invention. When rubber is used, the floor mat of the present invention can be manufactured using a heating press instead of the cold press 18.

The floor mat of the present invention can be used for applications in which the periphery of the floor mat is placed in contact with a wall, for example, an automobile floor mat, a store entrance floor mat, or a home entrance floor mat. .

[0034]

The floor mat according to the present invention has a deformable non-linear rib in the belt-shaped ridge, so that it has excellent adhesion to the floor wall and prevention of misalignment, and soil and the like between the floor mat and the floor. Can be prevented from entering. In addition, since the deformable non-linear ribs are excellent in shape retention, soil and the like can be held on the floor mat. Furthermore, since the belt-shaped protrusion has a deformable non-linear rib, the curl linking hardly occurs. Further, since the shape of the deformable non-linear rib does not appear on the upper surface of the band-shaped ridge, the design is excellent. Furthermore, since the adhesiveness to the floor wall is excellent, it is not necessary to perform a tape treatment or an overlock treatment, which is conventionally required, so that the manufacturing process is simplified and the manufacturing cost is reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of a floor mat according to one embodiment of the present invention as viewed from above.

FIG. 2 is an enlarged partial perspective view of a corner of the floor mat of FIG. 1 as viewed from above.

FIG. 3 is an enlarged partial perspective view of a corner portion of the floor mat of FIG. 1 viewed from a lower surface side.

FIG. 4 is an explanatory view schematically showing one arrangement mode of a deformable non-linear rib, and FIG. 4 (a) is a schematic bottom view,
FIG. 4B is a schematic sectional view.

FIG. 5 is an explanatory view schematically showing another arrangement of deformable non-linear ribs, FIG. 5 (a) is a schematic bottom view, and FIG. 5 (b) is a schematic sectional view. .

6A and 6B are explanatory views schematically showing still another arrangement of deformable non-linear ribs. FIG. 6A is a schematic bottom view, and FIG. 6B is a schematic sectional view. is there.

FIGS. 7A and 7B are explanatory views schematically showing yet another arrangement of deformable non-linear ribs. FIG. 7A is a schematic bottom view, and FIG. 7B is a schematic sectional view. is there.

FIG. 8 is an explanatory view schematically showing still another arrangement of deformable non-linear ribs, FIG. 8 (a) is a schematic bottom view, and FIG. 8 (b) is a schematic sectional view. is there.

9A and 9B are explanatory diagrams schematically showing still another arrangement of deformable non-linear ribs, FIG. 9A is a schematic bottom view, and FIG. 9B is a schematic sectional view. is there.

10A and 10B are explanatory views schematically showing still another arrangement of deformable non-linear ribs, FIG. 10A is a schematic bottom view, and FIG. 10B is a schematic sectional view. is there.

11A and 11B are explanatory views schematically showing still another arrangement of deformable non-linear ribs, FIG. 11A is a schematic bottom view, and FIG. 11B is a schematic sectional view. is there.

FIG. 12 is an explanatory view schematically showing still another arrangement mode of deformable non-linear ribs, FIG. 12 (a) is a schematic bottom view, and FIG. 12 (b) is a schematic sectional view. is there.

FIG. 13 is an explanatory view schematically showing a manufacturing process of the floor mat according to the present invention.

FIG. 14 is an explanatory view schematically showing another manufacturing process of the floor mat according to the present invention.

FIG. 15 is an explanatory view schematically showing still another manufacturing process of the floor mat according to the present invention.

[Explanation of symbols]

1. Floor mat; 2. Underlayer; 3. Surface layer; 4
..Flat portions; 4a.
.Grooves; 9. deformable non-linear ribs; 11a, 11b,
11c · belt conveyor; 12 · carpet; 13
..Elastomer sheet; 14..Extrusion molding nozzle; 1
5. Buffer part; 17 Auxiliary heater; 18 Cold press machine; 18a, 18b Mold; 19 Cutting machine; 20 Emboss press machine; 20a, 20b
Embossing roller; 21..projection; 51..periphery; 63.
.Side wall portion; 64 ceiling portion; 65a, 65b side surface of groove; 66 bottom surface of groove; 67, 68 edge of groove;
..Linear parts; 92. Bend parts; 93. Curved parts; 94.
-The lower surface of the deformable non-linear rib.

Claims (2)

[Claims] 1. A flat portion and a peripheral portion surrounding the flat portion, at least a part of the peripheral portion extends continuously substantially in parallel with the peripheral portion, and extends from a belt-like protruding portion protruding in an upper surface direction. An edge on the flat portion side of the band-shaped ridge and a peripheral edge on the peripheral side of the band-shaped ridge are substantially parallel to each other; Includes a groove extending the length of the ridge; said groove being discontinuous in the length of the ridge, one side of the groove, the bottom surface of the groove, and the bottom of the groove. The floor mat as described above, further comprising a plurality of deformable non-linear ribs provided continuously with the other side surface. 2. A sheet material maintained at a press-moldable temperature is sent to a pair of molds capable of press-molding the floor mat having the shape according to claim 1, and the sheet is pressed by the mold. The method for manufacturing a floor mat according to claim 1, wherein the floor mat is processed and cut into individual floor mats.