JPS5849185B2 - Manufacturing method for automotive floor mats - Google Patents

Description

Detailed Description of the Invention The present invention uses felt with excellent sound insulation performance, and in order to prevent the felt itself from corroding due to its water absorbing properties, the felt is replaced with a thermoplastic resin sheet such as PVC that has water repellency. The present invention relates to a method for manufacturing a floor mat that is coated with the floor mat and is formed in advance to match the shape of the floor so that it can be accurately laid on the floor of an automobile having a complex shape.

By the way, when manufacturing such floor mats,
Generally, a method of manufacturing is considered in which felt and thermoplastic resin sheets such as PvC covering the felt from the upper and lower surfaces are individually molded into a desired shape and then bonded together with an adhesive.

In other words, since the thermoplastic resin sheet such as PVC that covers the felt forms the surface material of the floor mat on at least one side of the felt, it is necessary to ensure the required thickness in consideration of beauty and durability. It is best to mold by vacuum forming, while felt is molded by pressure forming, so it is not possible to mold felt and a thermoplastic resin sheet such as PVC at the same time, and each must be molded separately. .

However, this general method is inefficient because it requires a step of molding felt, a step of molding two different-shaped thermoplastic resin sheets such as PVC, and a step of gluing them together. Since upper and lower molds are used to mold the two different shapes of thermoplastic resin sheets such as PVC, and separate vacuum molds are used to mold the two different shapes of thermoplastic resin sheets such as PVC, equipment costs are high and the cost is generally high. It has the disadvantage of being high.

The present invention aims to eliminate the drawbacks of such general manufacturing methods and provide a method that can be easily manufactured.
After vacuum forming a thermoplastic resin sheet such as VC using a vacuum mold that has an uneven shape corresponding to the shape of the floor of an automobile, a thermosetting resin or thermoplastic resin is applied to the thermoplastic resin sheet using the mold shape. PVC made by layering impregnated or mixed felt with a thermoplastic resin film interposed and lined with a stretchable woven or non-woven fabric.
, etc., and heat and press them using the vacuum forming mold and a mold paired with the mold to form the desired shape, and at the same time bond the felt and the thermoplastic resin sheets on both sides. The feature is that a mold for vacuum forming a thermoplastic resin sheet such as PvC is used as a pressurizing mold for one of the felts, and the thermoplastic resin sheet is bonded to both sides of the felt at the same time as the felt is formed, making it efficient and low cost. A floor mat is manufactured by covering felt with a thermoplastic resin sheet and integrally forming it into a predetermined shape.

An embodiment of the present invention will be described in detail below with reference to the drawings. First, a thermoplastic resin sheet 1 such as PVC having a thickness of 1.5 to 3 mm is given an uneven shape corresponding to the shape of the floor of an automobile. Vacuum forming is performed by a normal vacuum forming method using the vacuum forming mold 2 prepared (FIG. 1).

Since this thermoplastic resin sheet 1 forms the surface material of the floor mat, it must be set to a required thickness with durability in mind.

The thermoplastic resin sheet 1, which is then molded and in close contact with the mold 2, is pre-impregnated with a thermosetting resin such as a phenol resin, and has a thickness of 10 to 2 Qytun;
Felt 3 made of recycled cotton, chemically woven fabric, etc. is layered, and a thermoplastic resin film 4 such as polyethylene with a thickness of 0.5 to 0.8 mm is interposed therebetween to form a stretchable woven or nonwoven fabric 5. Relatively inexpensive PVC lined with a thickness of about 0.3 mm
(Fig. 2), and heated them using the vacuum mold 2 and the mold 1 paired with the mold 2 at a temperature of 120 to 180°C and a pressing force of 2 to 5 kg/cm. cr
ti, when heated and pressurized for 1 to 3 minutes (
3), the felt 3 is molded together with a heat-softened thermoplastic resin sheet 6 such as PVC, the thermoplastic resin sheet 6 is pressed onto the surface of the mold 7, and the phenol resin contained in the felt 3 is molded. Thermosetting resin such as molten felt 3
The thermoplastic resin sheet 1 and the felt 3, which are in close contact with one of the vacuum molds 2, are bonded together to maintain the predetermined shape state formed by the molds 2 and 1, and At the same time, a thermoplastic resin film 4 such as polyethylene is melted, and the felt 3 is similarly bonded to the thermoplastic resin sheet 6 lining the other stretchable woven or nonwoven fabric 5.

Note that this other thermoplastic resin sheet 6 is relatively light and is reinforced by being lined with a stretchable woven or nonwoven fabric 5, so that it will not tear during pressure molding with the molds 2 and 7. The thermoplastic resin film 4 is interposed between the felt 3 and the felt 3, so that the thermoplastic resin film 4 is firmly attached to the felt 3.

When the temperature of the thermoplastic resin sheets 1 and 6 on both sides of the felt 3 becomes below the softening point, the thermoplastic resin sheets 1 and 6 are removed from the molds 2 and γ and both thermoplastic resin sheets 1 and 6 protrude from the outer periphery of the felt 3.
The floor mat 8 as a product is obtained by joining the peripheral edges of the mats to each other using a high-frequency welder or the like (FIG. 4).

In the above embodiment, the felt 3 was impregnated with a thermosetting resin such as a phenol resin, but this may be not only a thermosetting resin but also a thermoplastic resin such as polyethylene or polypropylene, or a powder or a powder thereof. The fibers may be mixed into the felt 3.

Furthermore, a felt 3 and a thermoplastic resin film 4 are stacked on the thermoplastic resin sheet 1 that is in close contact with the vacuum mold 2.
The thermoplastic resin sheet 6 lined with a stretchable woven or nonwoven fabric 5 is heated in advance with a heater or the like to impart flexibility, and then the thermoplastic resin sheet 6 is placed in close contact with the vacuum mold 2. Even if it is stacked on the sheet 1 and pressed by the molds 2 and 1 at room temperature, it can be molded and bonded in the same manner as in the above embodiment.

As described above, the present invention utilizes a vacuum forming mold for vacuum forming a thermoplastic resin sheet such as PVC as a pressure molding mold for one of the felts, and simultaneously adheres the thermoplastic resin sheet to both sides of the felt at the same time as shaping the felt. Compared to the conventional manufacturing method in which felt and thermoplastic resin sheets that cover the felt from the top and bottom are individually molded and then bonded together with adhesive, felt can be made from thermoplastic resin sheets more efficiently and at lower cost. Floor mats can be manufactured that are covered and integrally molded into a predetermined shape.

Furthermore, the floor mat manufactured according to the present invention has a thermosetting resin or a thermoplastic resin contained in the felt.
Due to the integral structure in which the felt fibers are bonded together and the felt and the thermoplastic resin sheet covering it are bonded, durability is improved and it can be used for a long period of time.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention, and FIGS. 1 to 3 are explanatory diagrams of each manufacturing process, and FIG. 4 is a sectional view of a floor mat manufactured by the method of the present invention. 1...Thermoplastic resin sheet, 2...Vacuum mold, 3...Felt, 4...Thermoplastic resin film, 6... ...Thermoplastic resin sheet, 8...Floor mat.

Claims (1)

[Claims] I. After vacuum forming a thermoplastic resin sheet such as PVC using a vacuum molding mold that has an uneven shape corresponding to the shape of the floor of an automobile, a thermosetting resin or thermoplastic resin is applied to the thermoplastic resin sheet on the mold. A thermoplastic resin sheet such as PVC backed with a stretchable woven fabric or non-woven fabric is layered on top of the felt impregnated or mixed with a thermoplastic resin film, and these are placed in the vacuum molding mold. A method for producing a floor mat for an automobile, which comprises molding the felt into a desired shape by heating and pressurizing it using the mold and a pair of molds, and at the same time bonding the felt and thermoplastic resin sheets on both sides of the felt.