KR20180004989A - Making Method for Car Mat Using Plastic Line - Google Patents

Abstract

The present invention relates to a manufacturing method of a car mat using a plastic line, the manufacturing method which not only prevents floating of soil or dust inside the mat caused by flowing of air generated when a user steps on a mat disposed on an automobile indoor floor, but also can maintain shape of the mat and enable the mat to be easily cleaned. The manufacturing method of the present invention comprises the steps of: coupling a rim member (12) to edges of a mat member (11) to form an upper body (10); forming a lower body (20) to which the rim member (12) is coupled to be detached; and coupling the upper body (10) to be detached to the lower body (20), thereby integrating the upper body (10) with the lower body (20) to complete the car mat. The step of forming the upper body (10) includes the steps of: melting a PVC raw material; passing a melted raw material through a movable nozzle to form a plastic line, irregularly laying up the plastic line, and rapidly cooling the irregularly laid-up plastic line; passing the cooled plastic line between a pressing roll (51) and a heating roll (52) to form a mat with a double structure including an elastic portion (11a) of a fluffy texture and a flat portion (11b) of a compact texture; cutting the mat into a desired shape to complete the mat member (11); and coupling the rim member (12) to the edges of the mat member (11) to complete the upper body (10).

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0002]

The present invention relates to a method of manufacturing a car mat disposed on the floor of an automobile. More particularly, the present invention relates to a method of manufacturing a car mat, which prevents the soil or dust inside the mat from rising due to the flow of air generated when the mat is stepped on, And which can be easily manufactured while being easily cleaned.

In general, the floor of the vehicle is woven with a woven fabric to protect the floor of the room and to protect the outside noise.

In addition, an automobile mat is mounted on an indoor floor of a vehicle so as to comfortably keep the interior of the vehicle so that the occupant can ride comfortably, while preventing the foreign object on the occupant's shoes from falling off the vehicle mat.

The conventional automobile mats mainly use a fabric mat woven with a fabric, and the fabric mats are soft and infiltrate easily into the inside of the fabric mat, and the dirt and dust that have penetrated into the fabric mat Can not be easily shaken or cleaned, and the foreign matter can not be completely removed even if it is shaken or washed.

In order to solve the above problems, Korean Patent Registration No. 10-327098 (Automobile Mat Making Method), Korean Utility Model Publication No. 20-2009-12100 (Automobile Mat), and Korean Utility Model Publication No. 20-2009-12101 (Automotive Mat) was presented.

First, Korean Patent Registration No. 10-327098 (automobile mat manufacturing method) is a method of manufacturing an automobile mat, comprising the steps of mixing an antimicrobial agent with a soft corrugated material, a mixing step of mixing the compounded raw materials, A car forming step of forming a raw material having a predetermined width and a predetermined thickness in a plate shape; a car forming step of molding the car rendered plate with a roller molding machine to form a disk having a plurality of protruding elements on a body; And a heat treatment step of heating the cut circular plate by a heat treatment machine, wherein the heat treatment step comprises stacking the cut circular plates in a multi-stage manner in a heating furnace and heating the cut circular plates at a temperature of 120 to 160 DEG for 150 to 500 seconds So that the plurality of protruding elements are formed to form the support plate provided on the body will be.

In addition, Korean Utility Model Publication No. 20-2009-12100 (automobile mat) and Korean Utility Model Publication No. 20-2009-12101 (automobile mat) have a plurality of wide holes And a plurality of narrow concave grooves each having a size corresponding to that of the upper mat and accommodating foreign substances introduced through the holes, and a lower mat having a perimeter with a Velcro tape attached thereto, .

However, in the conventional automotive mat, there is an advantage that foreign matter such as dust is collected between the upper mat and the lower mat, and the upper mat and the lower mat are separated and cleaned. However, There is a problem in that the air is polluted by the generated shock or the exhausted air to the upper part when the user is carried.

That is, in the conventional automotive mat, as shown in FIG. 12, the foreign matter x such as soil or dust flowing through the through hole 1a of the upper mat 1 passes through the through hole 1a The foreign matter formed in the receiving groove 3a of the lower mat 3 is inserted into the receiving groove 3a of the lower mat 3 formed on the same line as the through hole 1a And thus the indoor air of the automobile is contaminated. That is, when the impact is applied to the outside or the person touches the mat, air flows into the space between the upper mat and the lower mat, so that the foreign matter (x) So that indoor air is polluted.

In order to solve such a problem, the applicant of the present invention has proposed a new type of synthetic resin sheet mat in a patent application (Patent Application No. 10-2015-0140890) which is the basis of the priority claim of the present invention, There is a problem that the mat member may be sagged during the sewing process with the velcro material. To prevent this, the shape retaining member along the edge of the mat member 6) must be installed.

Korean Registered Patent No. 10-1000888 Korean Patent Registration No. 10-1039088

SUMMARY OF THE INVENTION The present invention has been made in order to solve the problems of the prior art described above, and it is an object of the present invention to provide a method of manufacturing a car mat in which a mat member has a rigidity higher than a predetermined level, It has its purpose.

It is another object of the present invention to provide a method of manufacturing a car mat which can further improve the rigidity of the mat member by adding a simple process of applying an adhesive and can easily apply the adhesive.

According to another aspect of the present invention, there is provided a method of manufacturing a mat member, comprising: forming an upper member by joining a frame member to an edge of a mat member; forming a lower member to which the frame member is detachably coupled; Wherein the step of forming the upper body comprises the steps of melting the raw material of PVC, passing the molten raw material through a movable nozzle to form a synthetic resin yarn, Forming a mat composed of the elastic portion of the spongy structure and the flat portion of the dense structure by passing the cooled synthetic resin yarn between the press roll and the heating roll; To complete the mat member; and joining the frame member to the edge of the mat member, And then completing the step.

Further, according to the manufacturing method of the car mat of the present invention, it is characterized in that it further comprises a step of applying an adhesive to a portion where the heating roll is in contact before pressurizing and heating the cooled synthetic resin yarn.

According to the method of manufacturing a car mat of the present invention, the adhesive sprayer is sprayed with the adhesive agent sprayed on the upper side in a state in which the synthetic resin yarn that is cooled when the adhesive agent is applied is turned upside down.

  According to the method for producing a car mat of the present invention, the temperature of the heating roll is 150 to 250 ° C.

In addition, the step of flattening the cooled synthetic resin yarn between the upper roll and the lower roll is performed first, and then the synthetic resin yarn is passed between the press roll and the heating roll to form a double structure consisting of the elastic portion of the spongy structure and the flat portion of the dense structure Thereby forming a mat.

A method of manufacturing a car mat of the present invention includes the steps of forming an upper body 10 by joining a frame member 12 to an edge of a mat member 11 and a step of joining the frame member 12 (10) is detachably coupled to the lower body (20), thereby completing the car mat. The upper body (10) is formed by forming the upper body (DOTP), 15 to 25 parts by weight of activated carbon (CaCO ₃ ), and _{3 to} 7 parts by weight of polyethylene (PE) per 100 parts by weight of polyvinyl chloride (PVC) , 1-3 parts by weight of a dye, and 7-14 parts by weight of an environmental protection adjuvant in powder form; A raw material forming step of heating the mixed raw material to a temperature of 300 to 400 ° C to form a liquid form and then spraying it in a high pressure spraying manner to extract a coil of a thread shape; A cooling step of forming a resin raw material by laminating the formed yarns and then cooling the raw material into cooling water at 10 to 20 ° C to form a filament; A heating and drying step of passing the cooled resin raw material through a heating cylinder at 80 to 90 DEG C so that water is evaporated; An adhesive applying step of uniformly applying the adhesive to the upper surface of the resin cloth; A step of adhering an adhesive agent so that the upper surface of the resin material is flattened by coagulating and bonding the resin material coated with the adhesive while passing the adhesive agent between the heating roll and the pressing roll at 120 to 150 ° C; A cooling and drying step of drying the resin cloth to which the adhesive is adhered using the wind of an electric fan; And cutting the dried resin cloth into a desired shape to complete the mat member 11 and completing the upper member 10 by joining the rim member 12 to the edge of the mat member 11 .

Since the lower portion of the irregularly laminated synthetic resin sheet is pressed while being heated by using the heating roll when forming the mat member of the present invention, the lower side of the mat member forms a dense flat portion, The shape-retaining member is not required to be used, and the weight is reduced.

According to the method of manufacturing a car mat of the present invention, a portion of the synthetic resin yarn is adhered by an adhesive as the adhesive is applied before the irregularly laminated synthetic resin yarn is heated, so that the flat portion of the mat member becomes smoother, The stiffness is further improved.

1 is a flowchart showing a method of manufacturing a car mat according to the present invention.
2 is a reference diagram showing a pressing roll and a heating roll which are essential parts of the present invention.
3 is a reference diagram showing an adhesive sprayer which is a main part of the present invention.
4 is a reference view showing a top surface of a mat member manufactured by the present invention.
5 is a reference view showing a bottom surface of a mat member manufactured by the present invention.
6 is a flowchart showing another embodiment of the present invention.
7 is an exploded perspective view of a car mat manufactured by the present invention.
8 is a sectional view of a car mat manufactured by the present invention.
9 is a sectional view showing a modified example of the frame member according to the present invention.
10 is an enlarged cross-sectional view showing a cross-sectional structure of a mat member according to the present invention.
11 is a reference view showing another example of a car mat manufactured by the present invention.
12 is a plan view showing a lower body of a car mat according to the present invention.

Hereinafter, a method of manufacturing a car mat of the present invention will be described with reference to the accompanying drawings.

1 to 3, the method for manufacturing a car mat according to the present invention includes the steps of forming a top body 10 by joining a frame member 12 to an edge of a mat member 11, (10) is detachably coupled to the lower body (20) so as to integrate the lower body (20), thereby completing the car mat .

The step of forming the upper body 10 may include melting the raw material of PVC, forming a synthetic resin yarn by passing the molten raw material through a movable nozzle, randomly laminating the synthetic resin yarns so as to entangle each other, Passing the cooled synthetic resin yarn between the pressing roll 51 and the heating roll 52 to form a mat having a double structure consisting of the elastic portion 11a of the sparse structure and the flat portion 11b of the dense structure; , Completing the mat member 11 by cutting the mat into a desired shape and completing the upper member 10 by joining the frame member 12 to the edge of the mat member 11.

At this time, it may further include a step of applying an adhesive to a portion where the heated roll 52 is in contact before pressurizing and heating the cooled synthetic resin yarn. Examples of the adhesive include PVC and Emulsion PVC (EPVC) . This is because when the synthetic resin yarn is heated while pressurizing the synthetic resin yarn using the pressing roll 51 and the heating roll 52, the synthetic resin yarn melts and adheres to each other, and a part of the synthetic resin yarn is adhered to each other by the adhesive, So as to be further improved.

The heating roll 52 is a roll to which heat is applied, and the temperature of the heating roll is preferably about 150 to 250 ° C. If the temperature of the heating roll 52 is less than 150 ° C, the synthetic resin yarn is not melted and the flat portion 11b can not be formed. If the temperature of the heating roll 52 exceeds 250 ° C, And then the heating roll 52 may be pressed.

The pressing roll 52 is not subjected to heat, and is used merely for pressing. Therefore, the pressure roll is a part that melts the synthetic resin yarn so as to make the synthetic resin yarn as simple as possible without adhering to each other.

As a result, the upper portion is made of the elastic portion 11a having the texture as shown in Fig. 4, and the lower portion of the mat member 11 having the flat portion 11b having the fine structure as shown in Fig. 5 can be obtained. Here, the organization is used as a relative concept comparing 'elasticity' and 'flatness', which are 'granite' and 'dense'. In other words, the elastic part means that the structure is pale than the flat part, and the flat part means that the structure is more compact than the elastic part.

When applying the adhesive, it is preferable to apply the adhesive in a manner that the adhesive sprayer 53 injects the adhesive agent in a state where the cooled synthetic resin yarn is turned upside down and the upper side faces the upper surface, or the adhesive is applied using a roller.

Of course, when the adhesive is sprayed in the state that the synthetic resin yarn is turned upside down, the heating roll 52 should be disposed above the synthetic resin yarn and the pressing roll 51 should be disposed below the synthetic resin yarn. This is because the adhesive sprayed from the adhesive sprayer 53 is lowered by the gravity so that the adhesive agent is naturally applied to the synthetic resin yarn. At this time, the adhesive may be applied to the upper side of the synthetic resin using an application roller (not shown) without using the adhesive sprayer 53.

The step of applying the adhesive to the synthetic resin yarn or passing the cooled synthetic resin yarn between the upper roll and the lower roll to flatten the resin before passing the synthetic resin yarn between the pressing roll and the heating roll may be performed first. That is, after the cooled synthetic resin yarn is flattened, the adhesive is applied, and the flat portion 11b is formed by using the heating roll 52. In this case, the flatness of the mat member 11 is further increased.

As shown in FIG. 6, 40 to 60 parts by weight of dioctyl terephthalate (DOTP), 15 to 60 parts by weight of activated carbon (CaCO ₃ ) 15 per 100 parts by weight of polyvinyl chloride (PVC) , 3-7 parts by weight of polyethylene (PE), 1-3 parts by weight of a dye and 7-14 parts by weight of an environmental protection adjuvant in powder form; A synthetic resin yarn forming step of heating the mixed raw material to a temperature of 300 to 400 ° C to obtain a liquid form and then spraying the mixed raw material in a high pressure spraying manner to extract a coil of a yarn; A cooling step of forming a resin raw material by laminating the formed yarns and then cooling the raw material into cooling water at 10 to 20 ° C to form a filament; A heating and drying step of passing the cooled resin raw material through a heating cylinder at 80 to 90 DEG C so that water is evaporated; An adhesive applying step of uniformly applying an adhesive to an upper surface of the resin cloth (wherein the upper surface corresponds to a lower surface when a mat is manufactured, and the mat is manufactured upside down); An adhesive bonding step for allowing the adhesive tape to adhere to the surface of the resin cloth by allowing the adhesive tape to adhere to the adhesive tape; A cooling and drying step of drying the resin cloth to which the adhesive is adhered using the wind of an electric fan; A winding step of winding the cooled resin cloth around the roller; Cutting the wound resin material into a desired shape to complete the mat member 11; And joining the frame member 12 to the edge of the mat member 11 to complete the upper body 10.

In the raw material mixing step, the respective components are put in powder form and mixed using a stirrer. At this time, the environmental protection auxiliary agent is added to prevent environmental pollution caused by the resin, and may include a plasticizer and an antifoaming agent.

In the cooling step, the lamination height of the resin material is controlled by adjusting the lamination time. The winding step may be omitted if necessary.

By using the manufacturing method of the car mat of the present invention described above, a car mat including a mat member having a double structure can be manufactured.

As shown in FIGS. 7 to 10, a car mat is made of synthetic resin such as PVC resin, which is formed by lamination and pressurization and is integrally formed. The elastic part 11a on the upper side and the lower flat part 11b on the lower side, And is connected to the edge of the mat member 11 so as to form a groove portion into which the edge of the mat member 11 is inserted so as to form a mat member 11, (10) formed of a frame member (12) forming an outer shape of the upper body (10); And a lower body 20 which is integrally formed with the upper body 10 by detachably attaching the frame member 12 to an edge of the lower body 21 having the same shape as the mat member 11.

Since the lower side of the mat member 11 is formed of the dense flat portion 11b to increase the rigidity, the shape of the mat member 11 is maintained for a long time when the frame member 12 is engaged.

The structure for detachably coupling the upper body 10 and the lower body 20 may vary widely, but it is preferable to use a velcro structure. 8, a Velcro member 13 is attached to the bottom surface of the rim member 12, and a Velcro member 25 is attached to the upper surface of the lower member 20 so that the upper and lower members 10, (20) is coupled with the Velcro.

At this time, instead of attaching the Velcro member 13 to the bottom surface of the rim member 12, the bottom surface of the rim member 12 may be formed of a Velcro member. 9, a synthetic resin material rim 12a made of a top surface portion and a side surface portion and a bottom surface portion 12c made of a Velcro member detachably coupled to the Velcro member 25 attached to the upper surface of the edge of the lower body 20, (12b) may be integrated to form the frame member (12). In this case, it is possible to omit a part of the rim member 12 compared with the case where the Velcro member 13 is attached to the rim member 12, so that the material cost and weight can be saved.

On the other hand, the mat member 11 is formed by entangling a horizontal member formed in the range of ± 30 degrees with respect to the horizontal direction and a vertical member formed in the range of ± 30 degrees with respect to the vertical direction. At this time, it is preferable that at least three or more layers of the horizontal member are laminated. This prevents the soil or dust introduced into the gap of the mat member 11 from coming out upwardly by the recoil, For example.

The synthetic resin yarn of the upper body 10 is sandwiched from the mat member 11 when the mat member 11 is stepped on It prevents some dirt and dust from splashing back to the top.

12, the bottom body 21 is formed on the upper surface of the lower body 20 so as to provide a space in which the soil or dust contained in the mat member 11 can be received, A plurality of support ribs 22 or a plurality of support protrusions 23 arranged in an intersecting structure may be formed. 12 (a), it is preferable that the support ribs 22 are formed in an inclined structure as shown in FIG. 12 (a), and the support protrusions 23 are formed regularly or irregularly as shown in FIG. 12 (b) .

Also, the support ribs 22 and the support protrusions 23 can be formed in various ways, which can be formed in the form of a relief or a relief.

11, a plurality of protrusions 12 'are formed inside the frame member 12 when the upper body 10 is formed, and the protrusions 12' A recessed portion 11 'corresponding to each of the protruding portions 12' may be formed on the mat member 11 so that the mat member 11 and the frame member 12 are concave and convex. In this case, the joining between the mat member 11 and the frame member 12 can be firmly maintained without forming the frame member 12 into a 'C' shape in which the mat member 11 is inserted. .

The car mat is installed on an indoor floor of an automobile so that soil or dust falling from a shoe or the like is prevented from entering the room while a driver or a passenger boarding the car.

Foreign matter such as soil or dust falling from a shoe or the like is introduced into the lower portion of the mat member 11 through a gap formed in the mat member 11 and foreign matter flows into the lower portion of the mat member 11 due to the multi- So that it can not escape to the upper side. The foreign substances introduced into the lower portion of the mat member 11 are received and stacked on the bottom body 21 of the lower body 20 and are removed in cleaning.

When cleaning the car mat, the upper body 10 may be separated from the lower body 20 and cleaned separately. In the case of the upper body 10, water is sprayed on the mat member 11 to be washed and then dried. In the case of the lower body 20, the stacked foreign substances are removed, And then dried. Thereafter, the drying of the car mat is completed by attaching the dried upper body 10 to the lower body 20 by a Velcro-type method.

While the present invention has been described with respect to a method for manufacturing a car mat and a car mat manufactured by the method, the present invention can be applied not only to a car mat but also to various mats installed at the front of a door at a home or a school.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, Those skilled in the art will appreciate that many modifications and variations of the present invention are possible without departing from the spirit and scope of the invention. And all such modifications and changes as fall within the scope of the present invention are therefore to be regarded as being within the scope of the present invention.

10 ... upper body
11 ... mat member
11a ... elastic portion
11b ... flat portion
11 '... groove
12 ... frame member
12a ... border
12b ... bottom portion
12 '... protrusions
13 ... Velcro member
20 ... lower body
21 ... bottom body
22 ... support rib
23 ... support projection
25 ... Velcro member
51 ... pressure roll
52 ... heating roll
53 ... Adhesive sprayer

Claims (6)

Forming the upper body 10 by joining the frame member 12 to the edge of the mat member 11 and forming the lower body 20 to which the frame member 12 is detachably engaged, And completing the car mat by detachably coupling the upper body (10) to the lower body (20)
The step of forming the upper body (10)
Melting the PVC raw material;
Passing the molten raw material through a movable nozzle to form a synthetic resin yarn, randomly laminating the synthetic resin yarn, and rapidly cooling the synthetic resin yarn;
The cooled synthetic resin yarn is passed between the pressing roll 51 and the heating roll 52 to form a double structure mat composed of the elastic portion 11a of the coarse texture and the flat portion 11b of the dense texture;
Cutting the mat into a desired shape to complete the mat member 11,
And joining the frame member (12) to the edge of the mat member (11) to complete the upper body (10). The method according to claim 1,
Further comprising the step of applying an adhesive to a portion where the heating roll (52) is in contact before pressurizing and heating the cooled synthetic resin yarn. 3. The method of claim 2,
A method in which the adhesive sprayer 53 injects the adhesive agent on the upper side in a state in which the lower side of the synthetic resin yarn is turned upside down when applying the adhesive agent or a method of directly applying the adhesive agent on the bottom surface of the cooled synthetic resin yarn using a roller Wherein the synthetic resin mat mat is formed of a synthetic resin. The method according to claim 1,
Wherein the temperature of the heating roll (52) is 150 to 250 ° C. 5. The method according to any one of claims 1 to 4,
The step of flattening the cooled synthetic resin yarn between the upper roll and the lower roll is performed first,
And a synthetic resin yarn is passed between the pressure roll (51) and the heating roll (52) to form a mat having a double structure composed of an elastic portion (11a) of a sparse texture and a flat portion (11b) of a dense texture. ≪ / RTI > Forming the upper body 10 by joining the frame member 12 to the edge of the mat member 11 and forming the lower body 20 to which the frame member 12 is detachably engaged, And completing the car mat by detachably coupling the upper body (10) to the lower body (20)
The step of forming the upper body (10)
40 to 60 parts by weight of dioctyl terephthalate (DOTP), 15 to 25 parts by weight of activated carbon (CaCO ₃ ), _{3 to} 7 parts by weight of polyethylene (PE), 100 to 200 parts by weight of dyestuff 1 to 100 parts by weight of polyvinyl chloride (PVC) 3 to 7 parts by weight of an environmental protection adjuvant in powder form;
A raw material forming step of heating the mixed raw material to a temperature of 300 to 400 ° C to form a liquid form and then spraying it in a high pressure spraying manner to extract a coil of a thread shape;
A cooling step of forming a resin raw material by laminating the formed yarns and then cooling the raw material into cooling water at 10 to 20 ° C to form a filament;
A heating and drying step of passing the cooled resin raw material through a heating cylinder at 80 to 90 DEG C so that water is evaporated;
An adhesive applying step of uniformly applying the adhesive to the upper surface of the resin cloth;
A step of adhering an adhesive agent so that the upper surface of the resin material is flattened by coagulating and bonding the resin material coated with the adhesive while passing the adhesive agent between the heating roll and the pressing roll at 120 to 150 ° C;
A cooling and drying step of drying the resin cloth to which the adhesive is adhered using the wind of an electric fan;
Finishing the mat member 11 by cutting the dried resin cloth into a desired shape,
And joining the frame member (12) to the edge of the mat member (11) to complete the upper body (10).

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