KR20170039486A - Method for manufacturing a car mat and car mat manufactured by it - Google Patents

Method for manufacturing a car mat and car mat manufactured by it Download PDF

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Publication number
KR20170039486A
KR20170039486A KR1020150138687A KR20150138687A KR20170039486A KR 20170039486 A KR20170039486 A KR 20170039486A KR 1020150138687 A KR1020150138687 A KR 1020150138687A KR 20150138687 A KR20150138687 A KR 20150138687A KR 20170039486 A KR20170039486 A KR 20170039486A
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KR
South Korea
Prior art keywords
mat
eva
foamed
concave groove
sheet
Prior art date
Application number
KR1020150138687A
Other languages
Korean (ko)
Inventor
이상연
Original Assignee
글로벌더원코리아(주)
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 글로벌더원코리아(주) filed Critical 글로벌더원코리아(주)
Priority to KR1020150138687A priority Critical patent/KR20170039486A/en
Publication of KR20170039486A publication Critical patent/KR20170039486A/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/044—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of removable mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/08—Copolymers of ethylene
    • B29K2023/083—EVA, i.e. ethylene vinyl acetate copolymer

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Passenger Equipment (AREA)

Abstract

The method for manufacturing a foam mat for a vehicle and the foam mat for a vehicle manufactured by the method have excellent thermal stability and are advantageous for preventing thermal deformation and facilitating the degassing during the manufacturing process to improve the quality of the product, The shape can be deformed while having a hardness.

Description

TECHNICAL FIELD [0001] The present invention relates to a method of manufacturing a foam mat for a vehicle,

The present invention relates to a method of manufacturing a foam mat for a vehicle and a foam mat for a vehicle manufactured by the method, and is particularly advantageous for preventing thermal deformation due to its excellent thermal stability, The present invention relates to a method of manufacturing a rigid foam mat for a vehicle and a foam mat for a vehicle manufactured by the method.

The method for manufacturing a mat for a vehicle disclosed in the Utility Model Registration Application No. 20-2009-0013802 filed by the inventor of the present invention is disclosed in Korean Patent Registration No. 1274643 by the applicant of the present invention.

A method of manufacturing a mat for a vehicle disclosed in the above patent application includes:

a) a blending step of blending EVA (Ethylene-Vinyl Acetate) and a pigment; b) a primary mixing step of mixing the blended ingredients at 110 DEG C for about 12 minutes; c) adding a foaming agent and a cross-linking agent after the step b), and mixing the mixture at 110 DEG C for 2 minutes.

Such a manufacturing method is advantageous in that the foam mat is made lightweight by making the foam mat convenient to clean the mat, but there is a problem that the exchange period is shortened because deformation such as partial blowing up occurs during use for a long time due to the load of the passenger.

Application for Utility Model Registration No. 20-2009-0013802 Korea Patent No. 1274643

The present invention has been made in order to solve the above-mentioned problems, and it is an object of the present invention to improve the quality of a product by making it easy to prevent heat deformation and to prevent deformation during manufacturing, The present invention provides a method of manufacturing a foam mat for a vehicle which is deformable and hard, and a foam mat for a vehicle manufactured by the method.

According to the present invention, there is provided a method of manufacturing a foam mat for a vehicle,

a) 50 wt% of EVA (Ethylene-Vinyl Acetate), 15 wt% of EBA, 15 wt% of LDPE, 10 wt% of CaCO3, 5 wt% of a foaming agent, 1.0 wt% of a crosslinking agent, 0.5% by weight of ST-A) and 0.8% by weight of zinc oxide (Zn-O) and kneading in a kneader;

b) a second kneading step of mixing and kneading the kneaded material in the first kneading step with 1% by weight of an antimicrobial agent and fragrance;

c) a roll-milling step of passing the secondary kneaded product in the secondary kneading step through a roller at a temperature of 70 to 90 DEG C to form an EVA sheet;

d) placing the EVA sheet in a press having an upper mold having a plurality of first projections on the inner upper surface and a lower mold having a plurality of second projections on the inner bottom surface, applying heat and pressure for a predetermined time, A foaming step of foaming the EVA sheet by releasing the pressure to form first and second concave grooves on the upper and lower surfaces of the foamed EVA sheet;

e) cooling the EVA sheet and aging the EVA sheet; Aging step;

f) cutting the foamed EVA sheet horizontally to form two foamed first EVA mats and second EVA mats having the first and second concave grooves on the upper surface thereof, respectively; .

In addition, the manufacturing method of the present invention may further include the step of cutting the first EVA mat horizontally across the first concave groove of the first EVA mat to form a first bottom plate having a first hole and a first concave groove formed therein after step f) ,

Cutting the second EVA mat horizontally across a second recess of the second EVA mat to form a second bottom plate having a second top plate and a second concave groove formed with a second hole;

And a sewing step of cutting the first and second top plates and the first and second bottom plates into a desired mat shape and sewing the finished cloth along the edges.

The foam mat for vehicles of the present invention for achieving the above object is characterized by being manufactured by the above-described method.

First, bubbles in the EVA sheet 30a are smoothly discharged to the outside due to the added zinc oxide, so that the tissue density of the foamed EVA sheet 300 is improved.

Second, since the foam mat according to the present invention is improved in separation of the EVA sheet 300 foamed from the molds 10 and 20 due to the addition of stearic acid (ST-A), the EVA sheet So that the surface quality of the product can be improved.

Third, since the foam mat according to the present invention is improved in hardness due to the addition of calcium carbonate (CaCo3), deformation due to occupant load can be reduced as compared with the prior art.

Fourth, the foamed mat of the present invention can improve the thermal stability of the foamed sheet due to the addition of EBA, thereby reducing the thermal deformation more than ever.

Fifth, the EVA sheet is foamed in one of the molds 10 and 20 so that the grooves 310a and 320a are formed on the upper surface and the lower surface, respectively. Thereafter, the foamed EVA sheet 300 is subjected to first- The second cutting operation makes it possible to manufacture two pairs of foam mats each having a hole and a concave groove, thereby reducing the mold cost and simplifying the production of the foam mats.

Sixth, the grooves 310a and 320a of the first and second EVA mats 310 and 320 are cut horizontally across the holes 311a and 321a of the first and second top plates 311 and 321, And the concave grooves 312a and 322a of the first and second bottom plates 312 and 322 are formed so that the respective holes and the concave grooves can be precisely matched.

1 to 3 are schematic views for explaining a step of foaming an EVA sheet,
4 is a view for explaining a method of horizontally cutting a foamed EVA sheet,
Fig. 5 is a sectional view of the foamed EVA sheet of Fig. 4 cut horizontally and separated into first and second EVA mats,
FIG. 6A is a cross-sectional view of the first EVA mat of FIG. 5 cut horizontally across the concave grooves and separated into a first top plate and a first bottom plate;
FIG. 6B is a cross-sectional view of the second EVA mat of FIG. 5 cut horizontally across the concave grooves and separated into a second upper plate and a second lower plate;
7 and 8 are photographs showing a foamed EVA sheet
9 is a photograph of a foam mat for a vehicle manufactured by the method of the present invention.

The foam mat for a vehicle manufactured by the manufacturing method of the embodiment of the present invention includes a bottom plate having a concave groove capable of receiving foreign matter such as soil and dust on its top surface and a hole through which soil, It is possible to simplify the production of the foam mat comprising the formed top plate and to facilitate the degassing during the manufacturing process, thereby improving the quality of the product, making the surface smooth, and deforming the shape according to the shape of the bottom of the vehicle.

First, the structure of a foam mat for a vehicle manufactured by the manufacturing method of the embodiment of the present invention will be described.

Referring to FIG. 9, the foam mat is detachably coupled to the lower mat 420 and the upper mat 410 so that soil, dust, and the like can be received therebetween.

The lower mat 420 includes a lower plate 312 formed with a concave groove 312a capable of receiving foreign substances such as soil and dust on its upper surface and a lower plate 312 sewn on the edge of the lower plate 312, And a tape 340.

The upper mat 410 includes an upper plate 311 having an opening 311a through which soil or dust passes and an arm velcro tape (not shown) sewn on the edge of the upper plate 311 and attached to the male Velcro tape 340 330).

Dust or the like gathered in the concave groove 312a of the lower mat 420 through the hole 311a of the upper mat 410 is used as the upper mat 410, And the bottom mat 420 can be easily cleaned by being separated from the outside and can be easily cleaned. In use of the automobile, the interior of the automobile is housed in the concave groove of the lower mat 420, I can do it.

Hereinafter, a method for manufacturing a foam mat for a vehicle according to an embodiment of the present invention will be described.

1 to 4, first, 50 wt% of EVA (Ethylene-Vinyl Acetate), 15 wt% of EBA (ethylene butyl alcohol), 15 wt% of LDPE, 10 wt% of CaCO 3, 5 wt% , 1.0 wt% of a crosslinking agent, 1.5 wt% of a dye, 0.5 wt% of stearic acid (ST-A) and 0.8 wt% of zinc oxide (Zn-O) were mixed and kneaded in a kneader. The antimicrobial agent and the fragrance are mixed with water in an amount of 1% by weight, and the mixture is kneaded.

The secondary kneaded product is roll-milled while heating the kneaded product at a temperature of 70 to 90 DEG C to form an EVA sheet 30a having a thickness of 12 to 13 mm.

Then, the EVA sheet 30a is cooled for 24 hours and aged.

1, a lower mold 20 having an upper mold 10 having a plurality of first projections 11 on an inner upper surface thereof and a plurality of second projections 21 on an inner lower surface thereof, The EVA sheet 30a is placed in the cavity 1 of the pressure chamber 1 as shown in Fig. 2, the pressure is applied at a pressure of 5 kg / cm2 and a temperature of 140 to 150 deg. C for 30 minutes, The EVA sheet 30a is foamed.

At this time, as shown in FIG. 3, the EVA sheet is foamed and expanded in volume to fill the space of the cavity 1.

Further, due to the added zinc oxide, the bubbles in the EVA sheet 30a are smoothly discharged to the outside, and the tissue density of the foamed EVA sheet 300 is improved.

4, 7 and 8, when the upper mold 10 and the lower mold 20 are opened, a plurality of grooves 310a (see FIG. 7) are formed on the upper surface and the lower surface of the foamed EVA sheet 300 320a are formed.

At this time, the separation of the EVA sheet 300 foamed from the molds 10 and 20 is facilitated due to the addition of stearic acid (ST-A), thereby preventing the EVA sheet of the prior art from being pressed against the mold .

Further, the addition of calcium carbonate (CaCo3) improves the hardness and reduces the deformation caused by the load on the passenger.

In addition, due to the addition of EBA, the thermal stability of the foam sheet is improved and the thermal deformation can be reduced as compared with the prior art.

The foamed EVA sheet 300 has a thickness of about 25 mm, which is about two times larger in volume than before foaming. Further, the depth of the concave grooves 310a and 320a is about 9 mm and the median thickness d is about 7 mm.

After the foamed EVA sheet 300 is cooled, it is first cut horizontally along the cutting line c shown in Fig. 4 to form two first and second EVA mats (Fig. 310) < / RTI >

The cut surfaces of the first and second EVA mats 310 and 320 are formed as flat surfaces and the EVA mats 310 and 320 have concave grooves 310a and 320a on the upper surface thereof.

6A, a first upper plate 311 having a first hole 311a formed by horizontally cutting across a first concave groove 310a of the first EVA mat 310, A first bottom plate 312 having grooves 312a is formed.

The second EVA mat 320 is horizontally cut across the second concave groove 320a to form a second concave groove 322a and a second concave groove 322a formed on the second upper plate 321 and the second concave groove 322a. 2 bottom plate 322 is formed.

Next, the first and second top plates 311 and 321 and the first and second bottom plates 312 and 322 are cut into a desired mat shape, and as shown in Fig. 9, Sew and finish.

At this time, an arm velcro tape 330 is sewn on the edge of the upper plate 311 and a male velcro tape 340 is sewn on the edge of the lower plate 312 as a finishing cloth.

The EVA sheet is foamed in one mold 10 and the foamed EVA sheet 300 so that concave grooves 310a and 320a are formed on the upper and lower surfaces of the foam mat. Two pairs of foam mats having holes and concave grooves formed by horizontal first cutting and second cutting can be made, which reduces mold cost and simplifies the production of foam mats.

The concave grooves 310a and 320a of the first and second EVA mat 310 and 320 are horizontally cut to cut the holes 311a and 321a of the first and second top plates 311 and 321 And the concave grooves 312a and 322a of the first and second bottom plates 312 and 322 are formed so that the respective holes and the concave grooves can be precisely matched.

10 ... upper mold 11 ... first projection
20 ... Lower mold 21 ... Second projection
30a ... EVA sheet (before foaming) 300 ... EVA sheet (after foaming)
310, 320 ... first and second EVA mats 410, 420 ... upper and lower mats

Claims (3)

A method of manufacturing a foam mat for a vehicle,
a) 50 wt% of EVA (Ethylene-Vinyl Acetate), 15 wt% of EBA, 15 wt% of LDPE, 10 wt% of CaCO3, 5 wt% of a foaming agent, 1.0 wt% of a crosslinking agent, 0.5% by weight of ST-A) and 0.8% by weight of zinc oxide (Zn-O) and kneading in a kneader;
b) a second kneading step of mixing and kneading the kneaded material in the first kneading step with 1% by weight of an antimicrobial agent and fragrance;
c) a roll-milling step of passing the secondary kneaded product in the secondary kneading step through a roller at a temperature of 70 to 90 DEG C to form an EVA sheet;
and d) a lower mold (20) having an upper mold (10) having a plurality of first protrusions (11) on the inner upper surface and a plurality of second protrusions (21) The EVA sheet 30a is foamed by pressing the sheet 30a for a certain period of time after applying heat and pressure to release the pressure so that the first and second concave grooves 310a (320a) is formed on the surface of the substrate;
e) cooling the EVA sheet 30a, Aging step;
f) The foamed EVA sheet 300 is cut horizontally to form two foamed first EVA mat 310 and second EVA mat 320 having the first and second concave grooves 310a and 320a on the upper surface thereof, And a first cutting step of cutting the foamed mat to form a foamed mat. The method of claim 1, wherein after step f), a first upper plate (311) having a first hole (311a) formed by cutting horizontally across a first concave groove (310a) of the first EVA mat (310) A first bottom plate 312 having concave grooves 312a formed therein,
The second EVA mat 320 is horizontally cut across the second concave groove 320a to form a second concave groove 322a and a second concave groove 322a formed on the second upper plate 321 and the second concave groove 322a. 2 secondary cutting step of forming a lower plate 322;
i) After the step h), the first and second top plates 311 and 321 and the first and second bottom plates 312 and 322 are cut into a desired mat shape and sewed along the edges with a closure cloth And a sewing step of sewing the foam mat. A foam mat for a vehicle, which is manufactured by the production method of claim 1 or claim 2.
KR1020150138687A 2015-10-01 2015-10-01 Method for manufacturing a car mat and car mat manufactured by it KR20170039486A (en)

Priority Applications (1)

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KR1020150138687A KR20170039486A (en) 2015-10-01 2015-10-01 Method for manufacturing a car mat and car mat manufactured by it

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Application Number Priority Date Filing Date Title
KR1020150138687A KR20170039486A (en) 2015-10-01 2015-10-01 Method for manufacturing a car mat and car mat manufactured by it

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20090013802A (en) 2006-04-25 2009-02-05 미츠비시 레이온 가부시키가이샤 Active energy ray-curable coating composition and molded article having cured coating film of the composition
KR101274643B1 (en) 2011-10-03 2013-06-13 이상연 Method for manufacturing a car mat and car mat manufactured by it

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20090013802A (en) 2006-04-25 2009-02-05 미츠비시 레이온 가부시키가이샤 Active energy ray-curable coating composition and molded article having cured coating film of the composition
KR101274643B1 (en) 2011-10-03 2013-06-13 이상연 Method for manufacturing a car mat and car mat manufactured by it

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