WO2022190554A1

WO2022190554A1 - Floor carpet for vehicle and method for manufacturing same

Info

Publication number: WO2022190554A1
Application number: PCT/JP2021/047201
Authority: WO
Inventors: 新田島; 和樹岩野; 宙矢満永; 万里岩城
Original assignee: 林テレンプ株式会社
Priority date: 2021-03-11
Filing date: 2021-12-21
Publication date: 2022-09-15
Also published as: JPWO2022190554A1

Abstract

A floor carpet (1) for vehicle has a three-dimensional shape (2) and includes an opening (OP1) which passes through in the thickness direction (D3), the floor carpet (1) for vehicle comprising: a carpet layer (10) which is arranged on a surface (1a); a resin backing layer (15) which is integrated with a rear surface (10b) of the carpet layer (10); and additional resin layers (20) which partially exist on a rear side with respect to the resin backing layer (15). The floor carpet (1) for vehicle has a general portion (30) without the additional resin layers (20) in a region apart from an edge portion (34) and the opening (OP1) of the floor carpet (1) for vehicle, and an erected wall portion (32) which has the surface (1a) erecting from the general portion (30) toward the edge portion (34). The additional resin layers (20) exist in a periphery (38) of the opening (OP1) and in at least a part of the erected wall portion (32).

Description

Vehicle floor carpet and manufacturing method thereof

The present invention relates to a vehicle floor carpet having a three-dimensional shape and a manufacturing method thereof.

A known carpet used in automobiles is a floor carpet that is installed on the vehicle body panel from the floor panel to the toe board panel. The floor carpet is molded in a three-dimensional shape to match the body panel having a three-dimensional shape, and has openings through which mat hooks and the like are passed. Also, the floor carpet has a carpet layer facing the passenger compartment and a backing resin layer integrated with the back surface of the carpet layer. Japanese Unexamined Patent Application Publication No. 8-150865 discloses attaching a separate sound insulating sheet to the back surface of a flat portion without openings in a floor carpet.

JP-A-8-150865

In the vehicle floor carpet, for example, it is preferable that the area around the opening through which the mat hook or the like is passed and the toeboard section rising from the general section toward the front edge have high rigidity. In the above-mentioned technology, a separate sheet material is attached to the flat part of the floor carpet that has no openings. do not have.

The present invention discloses a vehicle floor carpet with enhanced rigidity while minimizing an increase in weight, and a manufacturing method suitable for manufacturing the vehicle floor carpet.

A vehicle floor carpet of the present invention is a vehicle floor carpet having a three-dimensional shape and having openings penetrating in the thickness direction,
a carpet layer disposed on the surface of the vehicle floor carpet;
a backing resin layer integrated with the back surface of the carpet layer;
an additional resin layer partially present on the back side of the backing resin layer,
The vehicle floor carpet includes a general portion without the additional resin layer in a portion away from the edge of the vehicle floor carpet and the opening, and a standing wall portion in which the surface rises from the general portion toward the edge. and
The additional resin layer has a mode in which it exists around the opening and at least a part of the standing wall portion.

Further, a method for manufacturing a vehicle floor carpet of the present invention is a method for manufacturing a vehicle floor carpet having a three-dimensional shape, comprising:
A width direction intersecting with the transfer direction in a state in which the base material including at least the carpet layer arranged on the surface of the vehicle floor carpet and the backing resin layer on the back surface of the carpet layer is transferred in the transfer direction. an additional resin supply step of partially supplying additional resin from the plurality of supply units onto the back surface of the base material while variably controlling the supply amounts of the plurality of supply units located at different positions in units of the supply units;
and a molding step of molding the base material and the additional resin such that an additional resin layer partially existing on the back side of the backing resin layer is formed from the additional resin.

According to the present invention, it is possible to provide a vehicle floor carpet with enhanced rigidity while minimizing an increase in weight, and a manufacturing method suitable for manufacturing the vehicle floor carpet.

1 is a perspective view schematically showing an example of a vehicle floor carpet; FIG. FIG. 2 is a cross-sectional view schematically showing an example of a vertical cross section along the front-rear direction of the vehicle floor carpet. FIG. 3 is a bottom view schematically showing an example of the back surface of the vehicle floor carpet. 4A to 4C are cross-sectional views schematically showing examples of vertical cross-sections of uneven shapes on the back surface of the standing wall. FIG. 5 is a diagram schematically showing an example of a method for manufacturing a vehicle floor carpet; FIG. 6 is a cross-sectional view schematically showing an example of a vertical cross section along the front-rear direction of the vehicle floor carpet provided with the cushioning material layer. FIG. 7 is a diagram schematically showing another example of a method for manufacturing a vehicle floor carpet; FIG. 8 is a cross-sectional view schematically showing an example of a vertical cross section of a vehicle floor carpet having ventilation holes in the backing resin layer.

Embodiments of the present invention will be described below. Of course, the following embodiments are merely illustrative of the present invention, and not all features shown in the embodiments are essential to the solution of the invention.

(1) Overview of technology included in the present invention:
First, an overview of the technology involved in the present invention will be described with reference to the examples shown in FIGS. 1-8. It should be noted that the figures of the present application are diagrams schematically showing examples, and the magnification in each direction shown in these figures may differ, and each figure may not match. Of course, each element of the present technology is not limited to specific examples indicated by reference numerals.
Further, in the present application, the numerical range "Min to Max" means the minimum value Min or more and the maximum value Max or less.

[Aspect 1]
As illustrated in FIGS. 1 to 3, 6, etc., a vehicle floor carpet 1 according to an aspect of the present technology has a three-dimensional shape 2 and an opening OP1 penetrating in the thickness direction D3. This is the floor carpet 1. The vehicle floor carpet 1 includes a carpet layer 10 arranged on the front surface 1a, a backing resin layer 15 integrated with the back surface 10b of the carpet layer 10, and a partial back side of the backing resin layer 15. It includes an additional resin layer 20 that is present. The vehicle floor carpet 1 has a general portion 30 without the additional resin layer 20 in a portion apart from the edge portion 34 of the vehicle floor carpet 1 and the opening OP1, and the surface 1a extends from the general portion 30 to the general portion 30 in a portion away from the opening OP1. A standing wall portion 32 rising toward an edge portion 34 is provided. The additional resin layer 20 exists on the periphery 38 of the opening OP<b>1 and at least part of the standing wall portion 32 .

In the vehicle floor carpet 1, the periphery 38 of the opening OP1 is likely to be subjected to a strong force, so high rigidity is required. In addition, in the vehicle floor carpet 1, the vertical wall portion 32 that rises toward the edge portion 34 is likely to be deformed such as warping, and there is a possibility that a gap may be generated by being pushed by a finger from the indoor SP1. Rigidity is required. In the above aspect 1, in the vehicle floor carpet 1, the additional resin layer 20 existing on the back side of the backing resin layer 15 exists in the periphery 38 of the opening OP1 and at least part of the standing wall portion 32, so that the periphery 38 of the opening OP1 And at least a part of the standing wall portion 32 is imparted with high rigidity. For example, when the additional resin layer 20 is present on at least a part of the standing wall portion 32, it is possible to prevent a gap from being generated due to, for example, being pushed by a finger from the room SP1.
As described above, Aspect 1 can provide a vehicle floor carpet with increased rigidity while suppressing an increase in weight as much as possible.
In some cases, the standing wall portion 32 rising toward the edge portion 34 is required to have not only high rigidity but also high sound insulation. When the additional resin layer 20 is present on at least a part of the standing wall portion 32, the additional resin layer 20 exerts sound insulation, so that the sound insulation of the vehicle floor carpet is improved.

Here, it is assumed that the three-dimensional shape of the vehicle floor carpet is a shape in which the height difference exceeds the thickness of the general portion.
The thickness direction of the vehicle floor carpet having a three-dimensional shape is a direction perpendicular to the surface of the vehicle floor carpet. Therefore, the thickness direction of the vehicle floor carpet has different directions depending on the parts of the vehicle floor carpet.
The opening of the vehicle floor carpet may be provided with an openable/closable lid formed of a slit.
The backing resin layer may include multiple layers. The additional resin layer may also include multiple layers.
The presence of the additional resin layer on the back side of the backing resin layer means that the additional resin layer is integrated with the back side of the backing resin layer, and that the additional resin layer is attached to the backing resin layer through a layer such as a cushioning material layer. It includes both being placed on the back side of the layer. Further, the additional resin layer may be present both around the opening and the standing wall, may be present around the opening without being present on the standing wall, or may be present on the standing wall without being present around the opening. may exist. Furthermore, the additional resin layer present on the standing wall portion may be present on the edge portion of the standing wall portion, or may be separated from the edge portion of the standing wall portion.
The general portion means the portion of the vehicle floor carpet which is remote from the edge and the opening and has no additional resin layer. Therefore, the vehicle floor carpet may have an edge portion having an additional resin layer in addition to the general portion and the vertical wall portion, or may include a portion remote from the edge portion and the opening and having the additional resin layer. may be provided.
In addition, the additional remark mentioned above is applied also to the following aspects.

[Aspect 2]
As illustrated in FIGS. 2, 3, 6, etc., the additional resin layer 20 may exist on at least a portion of the periphery 38 of the opening OP1 and on at least a portion of the standing wall portion 32. . In this aspect, at least a portion of the periphery 38 of the opening OP1 and at least a portion of the standing wall portion 32 are imparted with high rigidity, and the additional resin layer 20 present on at least a portion of the standing wall portion 32 provides sound insulation. Therefore, it is possible to provide a vehicle floor carpet with enhanced rigidity and sound insulation while suppressing an increase in weight as much as possible.

[Aspect 3]
As illustrated in FIGS. 2, 3, 6 and the like, the additional resin layer 20 may exist on at least a portion of the standing wall portion 32 . As illustrated in FIGS. 4A to 4C and the like, the additional resin layer 20 present on the vertical wall portion 32 may have an uneven shape 25 on the back surface 20b of the additional resin layer 20. FIG. The uneven shape 25 of the back surface 20b of the additional resin layer 20 present in the standing wall portion 32 gives the standing wall portion 32 high rigidity while suppressing an increase in weight as much as possible. Therefore, this aspect can effectively suppress the deformation of the standing wall portion rising from the general portion toward the edge portion.

Here, the uneven shape includes a plurality of parallel grooves, a plurality of parallel ridges, and the like. The directions of the grooves and ridges may be the width direction of the vehicle, the longitudinal direction of the vehicle, or the like.
The remarks mentioned above also apply to the following aspects.

[Aspect 4]
As exemplified in FIGS. 1 to 3 and the like, the vehicle floor carpet 1 may have an outwardly projecting portion 36 on the edge portion 34 . The additional resin layer 20 may be present on at least a portion of the extension 36 at the edge 34 . In the vehicle floor carpet 1, the extended portion 36 of the edge portion 34 is used as a handle or the like when the floor carpet 1 is assembled to the vehicle, and therefore is likely to be subjected to a strong force. In this aspect, in the vehicle floor carpet 1, the additional resin layer 20 present on the back side of the backing resin layer 15 is present on at least a part of the extending portion 36 of the edge portion 34. High rigidity is given to the part. Therefore, this aspect can effectively increase the rigidity of the outward extending portion at the edge of the vehicle floor carpet.

[Aspect 5]
By the way, as illustrated in FIGS. 5 and 7, a method for manufacturing a vehicle floor carpet 1 according to an aspect of the present technology is a method for manufacturing a vehicle floor carpet 1 having a three-dimensional shape 2, and includes the following steps. (A) and (B) are included.
(A) A base material 50 including at least the carpet layer 10 arranged on the front surface 1a of the vehicle floor carpet 1 and the backing resin layer 15 on the back surface 10b of the carpet layer 10 is transferred in the transfer direction D4. In this state, the additional resin 40 is partially supplied from the plurality of supply portions 120 while variably controlling the supply amounts of the plurality of supply portions 120 located at different positions in the width direction D5 intersecting the transfer direction D4 in units of the supply portions 120. an additional resin supply step ST1 in which the base material 50 is directly supplied onto the back surface of the base material 50;
(B) A molding step ST2 of molding the base material 50 and the additional resin 40 so that the additional resin layer 20 partially present on the back side of the backing resin layer 15 is formed from the additional resin 40 .

In the above aspect 5, while the base material 50 including at least the carpet layer 10 and the backing resin layer 15 is transferred in the transfer direction D4, variably controlled from each of the plurality of supply units 120 located at different positions in the width direction D5. The amount of additional resin 40 supplied is partially supplied onto the back surface of the base material 50 . When the material including the base material 50 and the additional resin 40 is molded, the additional resin layer 20 partially existing on the back side of the backing resin layer 15 is formed from the additional resin 40, and the vehicle floor having the three-dimensional shape 2 is formed. A carpet 1 is manufactured.
When attaching a separate sheet material to the back of the floor carpet, cost increases due to an increase in the number of parts, peeling of the sheet material due to poor adhesion, misalignment of the sheet material with respect to the opening, and 3D shapes such as standing walls. There is a disadvantage that follow-up is difficult.
In addition, when the additional resin is simply extruded onto the back surface of the base material, the additional resin layer is formed with a constant basis weight in the transport direction of the base material, so the degree of freedom for partially changing the basis weight of the additional resin layer is small. . In the fifth aspect, there are a plurality of supply units 120 at different positions in the width direction D5, and the supply amount of the additional resin 40 supplied from each supply unit 120 is variably controlled. , there is a large degree of freedom in partially changing the basis weight of the additional resin layer 20 . As a result, in the fifth aspect, it is possible to dispose the additional resin layer 20 having an appropriate basis weight in the portion of the vehicle floor carpet 1 where the rigidity is desired to be increased. Therefore, the above aspect 5 can provide a manufacturing method suitable for manufacturing a vehicle floor carpet with increased rigidity while suppressing an increase in weight as much as possible.

Here, the base material may be composed of a carpet layer and a backing resin layer, or may have a layer such as a cushioning material layer on the back surface of the backing resin layer in addition to the carpet layer and the backing resin layer.
Also, the vehicle floor carpet may be manufactured by attaching a separate member such as a cushioning material to the molding of the original material and the additional resin.

(2) Specific examples of vehicle floor carpet:
FIG. 1 schematically illustrates a vehicle floor carpet 1 installed in an automobile. FIG. 2 is a vertical cross-sectional view schematically illustrating the essential parts of an automobile 90 having the floor carpet 1, along the front-rear direction D1 at a position passing through the opening OP1 and the extension 36 in the floor carpet 1 shown in FIG. 1 schematically illustrates a vertical cross section. In the lower portion of FIG. 2, a schematic enlarged view of a vertical cross section near the opening OP1 in the automobile 90 is shown. FIG. 3 schematically illustrates the back surface 1b of the floor carpet 1. As shown in FIG. In the drawings of the present application, FRONT, REAR, LEFT, RIGHT, UP, and DOWN indicate front, rear, left, right, up, and down, respectively. The left and right positional relationship is based on the direction in which the front of the automobile 90 is viewed. Reference D1 indicates the longitudinal direction of the automobile, D2 indicates the lateral direction of the automobile, and D3 indicates the thickness direction of the floor carpet 1. As shown in FIG. For ease of illustration, the magnification ratios in the front-rear direction D1, the left-right direction D2, and the up-down direction may differ, and each drawing may not match. In particular, the cross-sections shown in FIGS. 2, 4, 6 and 8 are shown with exaggerated thicknesses.

In the example shown in FIG. 2, a cushioning material 70 is installed on the passenger compartment side surface 80a of the vehicle body panel 80 of the automobile 90, and the floor carpet 1 of the three-dimensional shape 2 is installed on the cushioning material 70. In the example shown in FIG. The vehicle body panel 80 shown in FIG. 2 includes a metal floor panel 81 that has unevenness (not shown) but is arranged substantially horizontally as a whole, and a metal floor panel 81 that rises obliquely forward from the front edge 81a of the floor panel 81. It includes a manufactured toe board 82 . Body panel 80 may include a metal dash panel that rises at a more nearly vertical angle from the leading edge of toeboard 82 . The dash panel functions as a partition wall between the vehicle compartment (an example of the interior SP1) and the engine room in the automobile 90, and the toe board 82 functions as an inclined portion that connects the dash panel and the floor panel 81 together.

The cushioning material 70 shown in FIG. 2 includes a flat portion 71 on the floor panel 81 and an inclined portion 72 on the toe board 82 . The flat portion 71 means a portion of the cushioning material 70 that is arranged substantially horizontally as a whole, and may have unevenness. The cushioning material 70 is used for at least one of shock absorption, sound absorption, and sound insulation and may be partially disposed on the vehicle body panel 80 . For the cushioning material 70, a fibrous material such as felt, a foamed resin such as a thermoplastic foam or polyurethane foam, a molded product of pulverized resin foam, a combination thereof, or the like can be used.

The floor carpet 1 on the cushioning material 70 has an opening OP1 penetrating in the thickness direction D3, and generally has a shape along the interior side surface 80a of the vehicle body panel 80. Here, the thickness direction D3 is a direction orthogonal to the surface 1a of the floor carpet 1, and has different directions depending on the parts of the floor carpet 1. As shown in FIG. As shown in FIGS. 1 and 2, the floor carpet 1 has a general portion 30 located above the floor panel 81 and a standing wall portion 32 rising from the general portion 30 toward the edge portion 34 on the surface 1a. The general portion 30 of this specific example is a portion of the floor carpet 1 away from the edge portion 34 and the opening OP1 where the additional resin layer 20 is absent. The general portion 30 generally extends along the floor panel 81 and exists on a flat portion that is generally horizontally arranged although there are irregularities.

The floor carpet 1 shown in FIGS. 1 and 3 includes a left portion 1d and a right portion 1e separated by a central recess 1c adapted to the console of the automobile 90, and a connecting portion 1f behind the central recess 1c. The left portion 1d is to the left of the central recess 1c and the connecting portion 1f. The right portion 1e is to the right of the central recess 1c and the connecting portion 1f. The connecting portion 1f connects from the left portion 1d to the right portion 1e at the rear portion of the floor carpet 1. As shown in FIG. The left portion 1d and the right portion 1e are provided with the above-described general portion 30 and standing wall portion 32, respectively. A floor carpet 1 has a three-dimensional shape 2 press-molded (thermoformed) along vehicle structures such as a console and a rocker panel. The three-dimensional shape 2 of the floor carpet 1 is assumed to be a shape whose height difference exceeds the thickness of the general portion 30 . The three-dimensional shape 2 includes a three-dimensional shape 2a of the surface 1a of the floor carpet 1 facing the room SP1 and a three-dimensional shape 2b of the back surface 1b of the floor carpet 1 opposite to the surface 1a.

The edge portion 34 of the floor carpet 1 includes a front edge portion, a rear edge portion, a left edge portion, a right edge portion, an inner edge portion along the central recessed portion 1c, and the like. A representative example of the standing wall portion 32 is the toeboard portion of the floor carpet 1, which is generally above the toeboard 82, as shown in FIG. The toeboard portion rises obliquely forward from the front edge 30a of the flat portion. In the floor carpet 1 shown in FIG. 1, the vertical wall portion 32 has a portion rising from the flat portion toward the rear edge portion, a portion rising from the flat portion toward the left edge portion, and a portion rising from the flat portion toward the right edge portion. It also exists in the portion rising from the flat portion and the portion rising from the flat portion toward the inner edge portion. Note that the present technology can be applied to the standing wall portion 32 as long as at least a portion of the standing wall portion 32 described above exists.

The floor carpet 1 may be transported from the manufacturer to the delivery destination while being folded at the folding portion 3 shown in FIG. The bent portion 3 shown in FIG. 3 includes a bent portion 3a along the left-right direction D2 and a bent portion 3b along the front-rear direction D1. In this case, for example, when the left and

right portions

1d and 1e are bent so as to close the surface 1a with the bent portion 3a as a base point, and the connecting portion 1f is bent so as to align the toeboard portions with the bent portion 3b as a base point, the floor The carpet 1 becomes compact.

The openings OP1 formed in the floor carpet 1 include an opening OP2 for inserting the mat hook, an opening OP3 for inserting the seat leg, an opening (not shown) for attaching the floor carpet 1 to the rocker panel or console, abbreviated as VIN. slit SL1 behind which information such as a vehicle identification number is arranged. The mat hooks are passed through the openings OP2 and engaged with the floor carpet 1 to fix the floor mat on the floor carpet 1. - 特許庁The seat legs are attached to the floor panel 81 through the openings OP3 to fix the seats present in the interior SP1 to the floor panel 81. The slit SL1 is a cut portion of the floor carpet 1 leaving a part around the opening. By forming the slit SL1 in the floor carpet 1, a lid portion capable of opening and closing the opening is formed in a state of being connected to the floor carpet 1. - 特許庁When the lid is substantially rectangular, cutting three sides of the substantially rectangular shape forms a slit SL1, and the remaining one side is used as a hinge to form an openable and closable lid connected to the floor carpet 1 . The opening OP1 may be located in a portion of the floor carpet 1 surrounded by the general portion 30 as shown in FIGS.

In addition, the floor carpet 1 has an extension portion 36 protruding outward from the edge portion 34 . The outward extension of the extension 36 means, for example, that the extension 36 extends forward from the front edge of the floor carpet 1 and that the extension 36 extends rearward from the rear edge of the floor carpet 1 . the extension 36 extends leftward from the left edge of the floor carpet 1; the extension 36 extends rightward from the right edge of the floor carpet 1; It means protruding from the inner edge along 1c in the direction of the central recess 1c, and so on. Therefore, the extensions 36 may be arranged at the front edge, left edge, right edge, inner edge, etc., in addition to the rear edge of the floor carpet 1 as shown in FIGS. The extending portion 36 is used as a handle or the like for holding the floor carpet 1 .

As an example of the cross-sectional structure of the floor carpet 1, the floor carpet 1 shown in FIG. , and an additional resin layer 20 partially present on the back side of the backing resin layer 15 . The additional resin layer 20 shown in FIG. 2 partially exists on the back surface 15 b of the backing resin layer 15 and is integrated with the backing resin layer 15 . Therefore, on the back surface 1b of the floor carpet 1, the back surface 20b of the additional resin layer 20 and the back surface 15b of the portion of the backing resin layer 15 not covered with the additional resin layer 20 are exposed. The floor carpet 1 includes a carpet layer 10 , a backing resin layer 15 and a partial additional resin layer 20 in a three-dimensional shape 2 . The additional resin layer 20 shown in FIGS. are placed in The opening OP<b>1 penetrates the carpet layer 10 , the backing resin layer 15 and the additional resin layer 20 . Note that the present technology can be applied as long as the additional resin layer 20 exists in the periphery 38 of the opening OP1 and at least part of the standing wall portion 32 .

The carpet layer 10 is a fiber material having air permeability, and gives the floor carpet 1 characteristics such as good design, good tactile feel, abrasion resistance, and sound absorption. For the carpet layer 10, a tufted carpet having a large number of napped piles on the surface 1a, a needle-punched carpet having a large number of fluffs on the surface 1a, or the like can be used. A tufted carpet is formed, for example, by piercing pile yarn into a base fabric such as a nonwoven fabric such as a spunbond nonwoven fabric or a knitted or woven fabric of various fibers with a tufting machine to raise the pile. A needle-punched carpet is formed, for example, by piercing a nonwoven fabric with a large number of hooked needles, entangling fibers, and forming fuzz on the surface. A synthetic fiber etc. can be used for the fiber which comprises the carpet layer 10. FIG. Polyolefin fibers such as PP (polypropylene) fibers, polyamide fibers, polyester fibers such as PET (polyethylene terephthalate) fibers, acrylic fibers, and the like can be used as the synthetic fibers.

The basis weight (weight per unit area) of the carpet layer 10 is not particularly limited, but can be, for example, approximately 150 to 1500 g/m ² .

The backing resin layer 15 has a shape retention function to maintain the three-dimensional shape 2 of the floor carpet 1, a sound insulation function to suppress noise from entering the room SP1, a damping function to suppress vibration from entering the room SP1, and the like. Demonstrate. The partial additional resin layer 20 has a reinforcing function that partially increases the rigidity of the floor carpet 1, a sound insulation enhancement mechanism that partially increases the sound insulation of the floor carpet 1, and a damping function that partially increases the damping performance of the floor carpet 1. Vibration enhancement function, etc. are exhibited.

A wide range of synthetic resins including elastomers can be used as the resin for forming the backing resin layer 15 and the additional resin layer 20, and thermoplastic resins are preferable in terms of thermoforming the floor carpet 1. The thermoplastic resins include polyolefin resins such as PE (polyethylene) resin and PP (polypropylene) resin, olefinic thermoplastic elastomers, vinyl resins such as vinyl acetate resin, ethylene vinyl acetate resin and vinyl chloride resin, acrylic resins, and AS (acrylonitrile). styrene) resins, ABS (acrylonitrile butadiene styrene) resins, materials obtained by adding additives such as fillers and coloring agents to these resins, and the like. As the thermoplastic resin, a thermoplastic resin having a low melting point of about 100 to 150° C. is preferable from the viewpoint of thermoformability. Inorganic fillers such as calcium carbonate, talc, barium sulfate, and metal oxides, metal powders, and the like can be used as the aforementioned fillers. The particle size of the filler is not particularly limited, but can be, for example, about 5 to 20 μm. When at least one of the backing resin layer 15 and the additional resin layer 20 contains a filler, the floor carpet 1 is provided with high sound insulation and vibration damping properties. High specific gravity backings, called massbacks, sometimes contain about 30 to 80% by weight of fillers. Of course, in order to make the floor carpet 1 lighter, at least one of the backing resin layer 15 and the additional resin layer 20 may be formed from synthetic resin containing no filler. For example, if the backing resin layer 15 is formed from a synthetic resin containing a filler, and the additional resin layer 20 is formed from a synthetic resin that does not contain a filler, the weight of the floor carpet 1 can be suppressed as much as possible and the required portions can be filled. In addition, the floor carpet 1 can be provided with a reinforcement function, a sound insulation enhancement function, a vibration damping enhancement function, and the like. Further, when the backing resin layer 15 is formed from a synthetic resin containing a filler, shrinkage of the resin after molding, for example, shrinkage of the thermoplastic resin after thermoforming due to cooling causes the vertical wall portion 32 to warp. In order to suppress deformation, the additional resin layer 20 may be formed from a synthetic resin containing a filler.

The resin for forming the additional resin layer 20 should be a highly compatible resin such as a resin of the same type as the resin used for the backing resin layer 15 in order to integrate the additional resin layer 20 with the backing resin layer 15 . preferable. For example, it is conceivable to use a filler-containing PE resin for the backing resin layer 15 and a filler-free LDPE (low-density polyethylene) resin for the additional resin layer 20 .

Although the basis weight of the backing resin layer 15 is not particularly limited, it can be, for example, about 80 to 2000 g/m ² .
Also, the backing resin layer 15 may be composed of a plurality of layers. For example, the backing resin layer 15 includes a first backing resin layer integrated with the back surface 10b of the carpet layer 10, and a second backing resin layer integrated with the back surface of the first backing resin layer. You can stay. The material of the second backing resin layer may be different from the material of the first backing resin layer. Different materials include the same base resin but different filler content.

The basis weight of the additional resin layer 20 is not particularly limited, but can be, for example, approximately 150 to 3000 g/m ² . The additional resin layer 20 may have different basis weights depending on the parts of the floor carpet 1 . The basis weight of the additional resin layer 20 present in the standing wall portion 32 is preferably larger than the basis weight of the additional resin layer 20 present in the periphery 38 of the opening OP1 from the viewpoint of suppressing deformation, such as warping, of the standing wall portion 32 . Further, when imparting high sound insulation performance to the vertical wall portion 32, it is preferable that the weight of the additional resin layer 20 existing on the vertical wall portion 32 is larger than that of the additional resin layer 20 existing on the periphery 38 of the opening OP1. Furthermore, in the additional resin layer 20 that is connected to one, the additional resin layer 20 may have a basis weight different depending on the part of the additional resin layer 20 .
Moreover, the additional resin layer 20 may be composed of a plurality of layers. For example, the additional resin layer 20 includes a first additional resin layer integrated with a portion of the back surface 15b of the backing resin layer 15, and the back surface of the first additional resin layer and the back surface 15b of the backing resin layer 15. It may include a second additional resin layer integral with the portion. The material of the second additional resin layer may be different from the material of the first additional resin layer.

In the floor carpet 1, the opening OP1 has a structure for passing mat hooks, seat legs, fixtures, etc., and for visually recognizing information behind the opening OP1. is required. The additional resin layer 20 existing around the opening OP1 in FIG. 3 is arranged to surround the entire circumference of the opening OP1. This imparts high rigidity to the perimeter 38 of the opening OP1. It should be noted that if the weight of the additional resin layer 20 is large, the rigidity of the periphery 38 of the opening OP1 is increased, and as a result, it is considered that it becomes difficult to pass the fixture or the like due to dimensional errors. Therefore, the basis weight of the additional resin layer 20 existing around the opening OP1 can be set to about 150 to 1200 g/m ² , for example. In addition, if the additional resin layer 20 is present all around the periphery 38 of the opening OP1, the stiffness of the periphery 38 of the opening OP1 increases, and as a result, it is conceivable that it becomes difficult to pass fittings or the like due to dimensional errors. Therefore, in order to reduce the work of inserting a fixture or the like, a part of the circumference 38 of the opening OP1 may have a part without the additional resin layer 20 . The additional resin layer 20 also exists around the slit SL1 shown in FIG. As shown in FIG. 3, when the additional resin layer 20 is present in the openable and closable lid surrounded by the slit SL1, the lid is pulled toward the back surface 1b due to shrinkage after thermoforming, so that the lid floats on the surface 1a. is suppressed, and the good design of the floor carpet 1 is maintained.

The standing wall portion 32 that rises toward the edge portion 34 is likely to be deformed such as warping, and may be pushed by a finger from the room SP1 to create a gap, so high rigidity is required. In some cases, the standing wall portion 32 is required to have not only high rigidity but also high sound insulation. For example, the toeboard portion of the floor carpet 1, which is generally above the toeboard 82, is located near the engine that generates sound, so it is preferable that the toeboard portion has high noise blocking performance. The additional resin layer 20 present on the toeboard portion shown in FIGS. 2 and 3 is present on a portion of the toeboard portion away from the edge 34 of the toeboard portion. Of course, an additional resin layer 20 may be present over the entire toeboard portion to increase the rigidity of the edge 34 in the toeboard portion. From the viewpoint of imparting high shape retention and sound insulation to the floor carpet 1, the basis weight of the additional resin layer 20 existing on the standing wall portion 32 should be larger than the basis weight of the additional resin layer 20 existing around the opening OP1. Preferably, for example, it can be about 1000 to 3000 g/m ² .

In order to effectively suppress the deformation of the vertical wall portion 32, the additional resin layer 20 present on the vertical wall portion 32 has an uneven shape 25 on the back surface 20b of the additional resin layer 20, as shown in FIGS. may be FIG. 4A schematically illustrates a vertical cross section of the uneven shape 25 on the back surface 20b of the additional resin layer 20 present on the vertical wall portion 32. FIG. The concave-convex shape 25 shown in FIG. 4A has a plurality of grooves 26 parallel to each other with the longitudinal direction directed to the left-right direction D2. Each groove 26 is on the back surface 20 b of the additional resin layer 20 .

The grooves 26 of the uneven shape 25 may reach the rear surface 15b of the backing resin layer 15 as illustrated in FIG. 4B. The concave-convex shape 25 shown in FIG. 4B is composed of a plurality of additional resin layers 20 arranged in parallel with the longitudinal direction facing the left-right direction D2. This case is also included in the fact that the additional resin layer 20 has the uneven shape 25 on the back surface 20b. Further, the uneven shape 25 of the back surface 20b of the additional resin layer 20 is not limited to a groove shape, and may be a plurality of ridges 27 as illustrated in FIG. 4C. The concave-convex shape 25 shown in FIG. 4C has a plurality of ridges 27 parallel to each other with their longitudinal directions directed in the left-right direction D2. However, it can be said that the uneven shape 25 shown in FIGS. 4A and 4B has a ridge between the grooves 26 , and the uneven shape 25 shown in FIG. 4C can be said to have a groove between the ridges 27 .
Furthermore, the directions of the grooves 26 and the ridges 27 are not limited to the left-right direction D2, and may be the front-rear direction D1 or the like.

The uneven shape 25 on the back surface 20b of the additional resin layer 20 shown in FIGS. 4A to 4C gives the vertical wall portion 32 high rigidity while minimizing the increase in weight. Therefore, the uneven shape 25 can effectively suppress the deformation of the standing wall portion 32 that rises from the general portion 30 toward the edge portion 34 of the floor carpet 1 . In particular, since the toeboard portion of the floor carpet 1 generally above the toeboard 82 has a large area, if the toeboard portion has the uneven shape 25, deformation of the toeboard portion can be effectively suppressed.

In addition to the toeboard portion, it is preferable to dispose an additional resin layer 20 on at least a portion of the standing wall portion 32 that rises toward the left and right edges of the floor carpet 1 in order to increase rigidity. The weight per unit area of the additional resin layer 20 at that portion can be, for example, about 600 to 1600 g/m ² . It is preferable to dispose an additional resin layer 20 on at least a part of the standing wall portion 32 that rises toward the inner edge portion along the central recessed portion 1c in the floor carpet 1 in order to increase rigidity and sound insulation. . The weight per unit area of the additional resin layer 20 at that portion can be, for example, about 600 to 1600 g/m ² .

The extending portion 36 present at the edge portion 34 of the floor carpet 1 is used as a handle or the like when the floor carpet 1 is assembled to the automobile 90, so a strong force is likely to be applied thereto, and high rigidity is required. In FIG. 3, the additional resin layer 20 is present on a portion of the extension 36 . The additional resin layer 20 may be present on the entire extending portion 36 . In either case, the additional resin layer 20 present on the back side of the backing resin layer 15 effectively increases the rigidity of the outward extension 36 at the edge 34 of the floor carpet 1 .

Since the folded portion 3 of the floor carpet 1 is folded during transportation, the presence of the thin additional resin layer 20 can suppress the occurrence of creases. Since the floor carpet 1 is bent at the bent portion 3, the weight of the additional resin layer 20 present at the bent portion 3 is preferably smaller than the weight of the additional resin layer 20 present at the vertical wall portion 32. For example, 150 It can be about 1000 g/m ² .

(3) Specific example of method for manufacturing vehicle floor carpet:
FIG. 5 schematically illustrates a method of manufacturing the vehicle floor carpet 1 shown in FIGS. The manufacturing method shown in FIG. 5 includes the following steps (A1) and (B1).
(A1) A state in which the base material 50 including the carpet layer 10 arranged on the front surface 1a of the vehicle floor carpet 1 and the backing resin layer 15 on the back surface 10b of the carpet layer 10 is transferred in the transfer direction D4. The additional resin 40 is partially supplied from the plurality of supply units 120 while variably controlling the supply amounts of the plurality of supply units 120 located at different positions in the width direction D5 orthogonal to the transfer direction D4 in units of the supply units 120. An additional resin supply step ST1 for supplying onto the back surface of the substrate 50 .
(B1) The base material 50 and the additional resin 40 are formed from the additional resin 40 so that the additional resin layer 20 partially existing on the back surface 15b of the backing resin layer 15 and integrated with the backing resin layer 15 is formed from the additional resin 40. molding step ST2 for molding.

FIG. 5 shows a carpet manufacturing apparatus 100 suitable for manufacturing the floor carpet 1. The carpet manufacturing apparatus 100 includes a transporter 110 that transports the base material 50 in the transport direction D4 with the back surface 15b facing upward, a plurality of supply units 120 that supply the additional resin 40 to the back surface 15b of the base material 50, a control unit 130, It includes a heating machine (not shown), a press molding machine 200, a cutting machine (not shown), and the like.

The base material 50 includes a substantially flat carpet layer 10 having a three-dimensional shape and a substantially flat backing resin layer 15 having a three-dimensional shape. As the base material 50, a long backed raw fabric or the like in which the carpet layer 10 and the backing resin layer 15 are laminated and wound into a roll can be used. The raw material 50 of this specific example is a long backed raw fabric including the thermoplastic backing resin layer 15 . In this case, the transfer direction D4 of the base material 50 is the longitudinal direction of the base material 50 . When the backing resin layer 15 contains a thermoplastic resin in a content that allows the backing resin layer 15 to exhibit thermoplasticity, the backing resin layer 15 has thermoplasticity.
A known conveyor such as a belt conveyor can be used for the transfer device 110 . When the backing resin layer 15 and the additional resin 40 have thermoplasticity, if the belt of the belt conveyor has a large number of ventilation holes, the backing resin layer 15 is preheated by heating with hot air or the like to melt the additional resin 40 . suitable for maintaining

The additional resin 40 becomes the additional resin layer 20 that partially exists in the floor carpet 1 . A material for forming the additional resin layer 20 may be used for the additional resin 40 . It is assumed that the additional resin 40 in this specific example has thermoplasticity. When the additional resin 40 contains a thermoplastic resin in a content that allows the additional resin 40 to exhibit thermoplasticity, the additional resin 40 has thermoplasticity.
The plurality of supply units 120 are arranged in the width direction D5 of the base material 50 . Note that the plurality of supply units 120 may be arranged in a direction deviated from the width direction D5 as long as they are located at different positions in the width direction D5. A plurality of supply units 120 shown in FIG. 5 include

supply units

121, 122, 123, 124, and 125 in order in the width direction D5. Of course, the number of supply units 120 may be two or more, four or less, or six or more. Each supply unit 120 has a nozzle 126 that discharges the additional resin 40 in a molten state so that the discharge speed can be changed. Being able to change the ejection speed of the additional resin 40 means that the ejection speed of the additional resin 40 can change between faster and slower while the base material 50 is moving in the transfer direction D4. do. Therefore, the supply amount of the additional resin 40 supplied to the back surface of the base material 50 can be changed according to the position in the transfer direction D4 and can be changed according to the position in the width direction D5. In other words, the supply amount of the additional resin 40 supplied to the back surface of the base material 50 can be changed according to the two-dimensional position on the plane along the transfer direction D4 and the width direction D5.
If each supply unit 120 is provided with a heater for heating the additional resin 40, it is preferable to keep the additional resin 40 in a molten state.

The control unit 130 controls the transfer speed of the base material 50 by the transfer device 110, the discharge speed of the additional resin 40 by each supply unit 120, and the like. The control of the ejection speed includes setting the ejection speed to 0, that is, not causing the supply unit 120 to eject the additional resin 40 . The control unit 130 individually controls the ejection speed of the additional resin 40 by the plurality of supply units 120 . For example, as shown in FIG. 5, the control unit 130 can cause the

supply units

122 and 124 to discharge the additional resin 40 without discharging the additional resin 40 from the

supply units

121, 123 and 125. It is possible to make the discharge speed of the additional resin 40 by 122 and the discharge speed of the additional resin 40 by the supply part 124 different. Here, the basis weight of the additional resin layer 20 can be increased by increasing the ejection speed of the additional resin 40 by each supply unit 120, and the basis weight of the additional resin layer 20 can be increased by decreasing the ejection speed of the additional resin 40 by each supply unit 120. can be reduced. FIG. 5 shows the additional resin 41 ejected onto the back surface 15b at a relatively high ejection speed, and the additional resin 42 ejected onto the back surface 15b at a relatively slow ejection speed. The basis weight of the additional resin layer 20 formed from the additional resin 41 is larger than the basis weight of the additional resin layer 20 formed from the additional resin 42 . Further, when the transfer speed of the base material 50 by the transfer device 110 is slowed down, the basis weight of the additional resin layer 20 can be increased over the entire width direction D5, and when the speed of transfer of the base material 50 by the transfer device 110 is increased, the thickness of the base material 50 in the width direction D5 can be increased. The basis weight of the additional resin layer 20 can be reduced over the entirety. The control unit 130 controls the transfer speed of the base material 50 by the transfer device 110, the discharge speed of the additional resin 40 by each supply unit 120, and the etc. Since the substantially flat base material 50 is thermoformed into the three-dimensional shape 2, by changing the supply amount of the additional resin 40 according to the expansion rate (elongation rate) according to the part of the base material 50, the floor carpet 1 can be expanded. Weight and performance may be optimized. For example, in the base material 50 , it is conceivable that the amount of the additional resin 40 supplied to the portion to be the standing wall portion 32 is larger than that to the portion to be the general portion 30 .
A computer or the like that includes a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), etc. and executes a control program can be used as the control unit 130 .

In the additional resin supply step ST1, the base material 50 is transferred in the transfer direction D4 by the transfer device 110, and the variably controlled amount of the additional resin 40 supplied from each supply unit 120 partially covers the backing resin layer 15 of the base material 50. It is supplied to the back surface 15b. A material including the base material 50 and the additional resin 40 is cut by a cutting machine (not shown) into a size including the floor carpet 1 and carried into a heater (not shown).

The molding process ST2 shown in FIG. It includes a cutting step ST23 for cutting into pieces.

In the heating step ST21, a heater (not shown) heats the material including the base material 50 and the additional resin 40 to a temperature slightly higher than the melting point of the thermoplastic resin contained in the base material 50 and the additional resin 40. A suction heater (hot air circulation heater), an infrared heater, or the like can be used as the heater. The heated material is carried into press molding machine 200 .

In the press process ST22, the press molding machine 200 press-molds the material heated in the heating process ST21. Press molding is included in thermoforming. A press molding machine 200 shown in FIG. 5 is provided with an upper mold 201 and a lower mold 202 that constitute a press mold so that they can approach and separate from each other. The upper mold 201 is a mold having a mold surface that matches the shape of the back surface 1b of the floor carpet 1 on its opposite surface. Therefore, the mold surface of the upper mold 201 has an uneven shape that matches the uneven shape 25 on the back surface 20 b of the additional resin layer 20 . Although not shown, the mold surface of the upper mold 201 may have a shape for imprinting a mark such as a material mark or a CCC (China Compulsory Certificate) mark on the back surface 20 b of the additional resin layer 20 . The lower mold 202 is a mold having a mold surface matching the shape of the surface 1a of the floor carpet 1 on the opposite surface. Therefore, the material including the base material 50 and the additional resin 40 is placed upside down between the

molds

201 and 202 . Of course, the arrangement of the materials including the base material 50 and the additional resin 40 may be arranged according to the positional relationship of laying on the automobile 90 . Press molding may be hot pressing with heating or cold pressing without heating. When the press molding machine 200 brings the upper mold 201 and the lower mold 202 close to each other, the material is press molded into the three-dimensional shape 2 . An uneven shape 25 is formed on the back surface 20b of the additional resin layer 20, and a mark is stamped when the mold surface of the upper mold 201 has a shape for stamping a mark. This eliminates the need to prepare seals with marks. When the temperature of the material drops below the melting point of the thermoplastic resin after press molding and the thermoplastic resin solidifies, the three-dimensional shape 2 is maintained with the backing resin layer 15 and the additional resin layer 20 integrated. The press step ST22 may include a cooling step of cooling the press-molded material. When the press molding machine 200 separates the upper mold 201 and the lower mold 202, the press molded product of the three-dimensional shape 2 can be taken out. The press-formed product taken out from between the

molds

201 and 202 is carried into a cutting machine (not shown).

In the cutting step ST23, the cutting machine cuts the cooled press-molded product into the shape of the floor carpet 1. The cutting machine cuts the outer periphery of the press-formed product, and cuts the press-formed product so as to form the opening OP1 including the slit SL1 inside the outer periphery. Thereby, the floor carpet 1 shown in FIGS. 1 to 3 is obtained. As the cutting machine, a cutting machine having a cutting blade, a cutting machine that cuts by water jet, or the like can be used. In addition to cutting with a cutting blade and water jet cutting, the press-molded product can be cut by manual cutting using a cutter.

As described above, while the base material 50 is being transported in the transport direction D4, the supply amount of the additional resin 40 variably controlled from each of the plurality of supply units 120 located at different positions in the width direction D5 is partially supplied. is supplied onto the back surface of the base material 50 . When the material including the base material 50 and the additional resin 40 is molded, the partial additional resin layer 20 integrated with the back surface 15 b of the backing resin layer 15 integrated with the back surface 10 b of the carpet layer 10 is formed by the additional resin 40 . A floor carpet 1 having a three-dimensional shape 2 is manufactured. As shown in FIGS. 1 to 3, the floor carpet 1 has an opening OP1 penetrating in the thickness direction D3, and has a vertical wall portion 32 rising from the general portion 30 toward the edge portion 34, and an additional resin layer. 20 are present in the perimeter 38 of the opening OP1 and part of the standing wall 32 . For example, the existence of the additional resin layer 20 around the opening OP1 in the floor carpet 1 imparts high rigidity to the surrounding 38 of the opening OP1. Since the additional resin layer 20 is present in part of the vertical wall portion 32 of the floor carpet 1, the vertical wall portion 32 is provided with high rigidity and high sound insulation. Therefore, the vehicle floor carpet 1 of this specific example has a minimized increase in weight, and has high rigidity and high sound insulation.

When a separate sheet material is attached to the back surface 1 b of the floor carpet 1 , the cost increases due to an increase in the number of parts, peeling of the sheet material due to poor adhesion, misalignment of the sheet material with respect to the opening OP 1 , and vertical wall portion 32 . There is a disadvantage that following the three-dimensional shape 2 is difficult.
Further, when the additional resin 40 is simply extruded onto the back surface of the base material 50, the additional resin layer is formed with a constant basis weight in the transfer direction D4 of the base material 50, so the basis weight of the additional resin layer is partially changed. less freedom. In this specific example, there are a plurality of supply units 120 at different positions in the width direction D5, and the supply amount of the additional resin 40 supplied from each supply unit 120 is variably controlled. , there is a large degree of freedom in partially changing the basis weight of the additional resin layer 20 . As a result, the additional resin layer 20 having an appropriate basis weight can be arranged in a portion of the floor carpet 1 where rigidity is desired to be increased. Therefore, the manufacturing method of this specific example is suitable for manufacturing the vehicle floor carpet 1 with increased rigidity while suppressing an increase in weight as much as possible.

Separate members may be added to the floor carpet 1 shown in FIGS. For example, a separate member such as a cushioning material 70 may be attached to the rear surface 1b of the floor carpet 1 .

(4) Specific example of floor carpet comprising another layer between the backing resin layer and the additional resin layer:
As illustrated in FIG. 6, the additional resin layer 20 may be separated from the backing resin layer 15 . FIG. 6 schematically illustrates a vertical cross section along the front-rear direction D1 of the vehicle floor carpet 1 including the cushioning material layer 60 between the backing resin layer 15 and the additional resin layer 20. As shown in FIG. In the lower portion of FIG. 6, a schematic enlarged view of a vertical cross section near the opening OP1 in the floor carpet 1 is shown. Among the plurality of elements shown in FIG. 6, elements that are substantially the same as or similar to the elements shown in FIGS. 1 to 3 are given the reference numerals shown in FIGS.
The three-dimensional shape of the surface 1a of the floor carpet 1 is the same as the three-dimensional shape 2a shown in FIG. Although the partial additional resin layer 20 is integrated with the rear surface 60b of the cushioning material layer 60, the arrangement of the additional resin layer 20 is the same as the arrangement of the additional resin layer 20 shown in FIG. The opening OP<b>1 penetrates the carpet layer 10 , the backing resin layer 15 , the cushioning material layer 60 and the additional resin layer 20 . The materials described above can be used for the carpet layer 10, the backing resin layer 15, and the additional resin layer 20. FIG.

The cushioning material layer 60 is integrated with the back surface 15 b of the backing resin layer 15 integrated with the back surface 10 b of the carpet layer 10 . The cushioning material layer 60 is used for at least one of impact absorption, sound absorption, and sound insulation, like the cushioning material 70 shown in FIG. good. The cushioning material layer 60 can be made of a fibrous material such as felt, a foamed resin such as a thermoplastic foam or polyurethane foam, a molded product of pulverized foamed resin, a combination thereof, or the like. Thermoplastic fibers, a combination of heat-resistant fibers and thermoplastic fibers, and the like can be used for the above-mentioned fiber materials, and recycled recoil fibers can also be used. Inorganic fibers such as glass fibers can be used as the heat-resistant fibers. Thermoplastic fibers can be thermoplastic resin (including thermoplastic elastomer) fibers, thermoplastic resin fibers with additives, etc. Polyester fibers such as PET fibers, PP fibers and PE fibers can be used. Polyolefin-based fibers such as fibers, polyamide-based fibers, combinations of these fibers, and the like can be used. Fibers having a conjugate structure, such as a core-sheath structure and a side-by-side structure, can also be used for the aforementioned fiber material.
Of course, materials that can be used for the cushioning material layer 60 can also be used for the cushioning material 70 described above.

The basis weight of the cushioning material layer 60 is not particularly limited, but can be, for example, about 600 to 3000 g/m ² .
Moreover, the cushioning material layer 60 may be composed of a plurality of layers. For example, the cushioning layer 60 includes a first cushioning layer integrated with the back surface 10b of the carpet layer 10 and a second cushioning layer integrated with the back surface of the first cushioning layer. You can stay. The material of the second cushioning layer may be different than the material of the first cushioning layer.

The additional resin layer 20 shown in FIG. 6 partially exists on the back surface 60b of the cushioning material layer 60 and is integrated with the back surface 60b of the cushioning material layer 60. Therefore, on the back surface 1b of the floor carpet 1, the back surface 20b of the additional resin layer 20 and the back surface 60b of the portion of the cushioning material layer 60 not covered with the additional resin layer 20 are exposed. The additional resin layer 20 integrated with the back surface 60 b of the cushioning material layer 60 partially exists on the back side of the backing resin layer 15 .

(5) Specific example of method for manufacturing vehicle floor carpet provided with cushioning material layer:
FIG. 7 schematically illustrates a method of manufacturing the vehicle floor carpet 1 shown in FIG. Among the plurality of elements shown in FIG. 7, elements that are substantially the same as or similar to the elements shown in FIG. 5 are given the reference numerals shown in FIG. The manufacturing method shown in FIG. 7 includes the following steps (A2) and (B2).
(A2) Carpet layer 10 disposed on front surface 1a of vehicle floor carpet 1, backing resin layer 15 on back surface 10b of carpet layer 10, and cushioning material layer overlaid on back surface 15b of backing resin layer 15 60 is being transferred in the transfer direction D4, the supply amount of a plurality of supply units 120 at different positions in the width direction D5 orthogonal to the transfer direction D4 is variably controlled for each supply unit 120. An additional resin supply step ST1 in which the additional resin 40 is partially supplied onto the back surface of the base material 50 from the plurality of supply units 120 while the supply portion 120 is being supplied.
(B2) The base material 50 and the base material 50 and the A molding step ST2 for molding the additional resin 40 .

The floor carpet 1 including the cushioning material layer 60 can also be manufactured by the carpet manufacturing apparatus 100. In the manufacturing method shown in FIG. 7, the carpet manufacturing apparatus 100 may be provided with a lamination device for laminating the cushioning material layer 60 on the backing resin layer 15 of the long backed raw fabric including the carpet layer 10 and the backing resin layer 15. good. A base material 50 shown in FIG. 7 is a long material in which a cushioning material layer 60 is superimposed on the backing resin layer 15 of a long backing material including a thermoplastic backing resin layer 15 . The buffer material layer 60 shall contain a thermoplastic resin.

In the additional resin supply step ST1, the base material 50 is transferred in the transfer direction D4 by the transfer device 110, and the supply amount of the additional resin 40 variably controlled from each supply unit 120 is partially applied to the cushioning material layer 60 of the base material 50. It is supplied to the back surface 60b. A material including the base material 50 and the additional resin 40 is cut by a cutting machine (not shown) into a size including the floor carpet 1 and carried into a heater (not shown). In the heating step ST21, a heater (not shown) heats the material including the base material 50 and the additional resin 40 to a temperature slightly higher than the melting point of the thermoplastic resin contained in the base material 50 and the additional resin 40. In the press step ST22, the press molding machine 200 press molds the material heated in the heating step ST21. The press-formed product taken out from between the

molds

201 and 202 is carried into a cutting machine (not shown). In the cutting step ST23 , the cutting machine cuts the cooled press-formed product into the shape of the floor carpet 1 . Thereby, the floor carpet 1 shown in FIG. 6 is obtained.

The floor carpet 1 shown in FIG. 6 includes a partial additional resin layer 20 integrated with the back surface 15b of the backing resin layer 15 and the back surface of the cushioning material layer 60, and has a three-dimensional shape 2. The floor carpet 1 shown in FIG. 6 also has an opening OP1 penetrating in the thickness direction D3, the surface of which is provided with a vertical wall portion 32 rising from the general portion 30 toward the edge portion 34, and the additional resin layer 20 is formed in the opening OP1. It exists in the periphery 38 and part of the standing wall portion 32 . Therefore, the floor carpet 1 shown in FIG. 6 also has a minimized increase in weight, and has high rigidity and high sound insulation.

(6) Modification:
Various modifications of the present invention are conceivable.
For example, the vehicle floor carpet to which the present invention can be applied is not limited to the floor carpet installed on the floor of the passenger compartment, and may be a floor carpet installed on the floor of the luggage compartment.
Vehicles on which the vehicle floor carpet can be installed are not limited to vehicles equipped with an engine that burns gasoline or the like, and may be electric vehicles or the like. A floor carpet installed in an electric vehicle has a large opening for a battery pack at the rear. High rigidity is also required around such a large opening. The presence of the additional resin layer at least partially around the large opening for the battery pack in the floor carpet for electric vehicles imparts high rigidity around the large opening for the battery pack.
The backing resin layer 15 may have ventilation holes for enhancing the sound absorption of the floor carpet 1 .

FIG. 8 is a vertical cross-sectional view schematically illustrating a main part of the vehicle floor carpet 1 having a plurality of ventilation holes 18 in the backing resin layer 15. As shown in FIG. Among the plurality of elements shown in FIG. 8, elements that are substantially the same as or similar to the elements shown in FIG. 2 are given the reference numerals shown in FIG.
The backing resin layer 15 shown in FIG. 8 has a plurality of ventilation holes 18 penetrating in the thickness direction D3, and allows air to flow between the carpet layer 10 and the cushioning material 70 to exhibit a sound absorbing function. The floor carpet 1 having the air-permeable backing resin layer 15 has a high sound absorbing property, but also has a property that sound easily passes through the back surface 1b into the room SP1. For example, since the toeboard portion of the floor carpet 1 is located near the engine that generates sound, it is preferable that the toeboard portion has high sound insulation. The toeboard portion shown in FIG. 8 comprises a partial additional resin layer 20 integrated with the back surface 15b of the backing resin layer 15 having the air holes 18 therein. As a result, the floor carpet 1 exhibits a high sound absorbing function due to the ventilation holes 18 in the general portion 30, and a high sound insulating function due to the additional resin layer 20 existing in the toe board portion. Therefore, the floor carpet 1 including the backing resin layer 15 having a plurality of ventilation holes 18 penetrating in the thickness direction D3 and the additional resin layer 20 partially present on the back side of the backing resin layer 15 is reduced in weight. The increase is suppressed as much as possible, and it has high rigidity, high sound absorption, and high sound insulation.

Also, even if the backing resin layer 15 of the floor carpet 1 shown in FIG. 6 has a plurality of ventilation holes, the above effects can be obtained.

It should be noted that the additional resin layer 20 is not limited to being present both on the periphery 38 of the opening OP1 and on the vertical wall portion 32, and may be present on the periphery 38 of the opening OP1 without being present on the vertical wall portion 32, or may be present on the periphery 38 of the opening OP1. It may be present in the standing wall portion 32 without being present in the periphery 38 of the . If the additional resin layer 20 exists around 38 of the opening OP1, the floor carpet 1 may not have the vertical wall portion 32, and if the additional resin layer 20 exists in the vertical wall portion 32, the floor carpet 1 may have no opening OP1. .

As described above, the present technology provides the vehicle floor carpet 1 having the opening OP1 penetrating in the thickness direction D3,
a carpet layer 10 arranged on the surface 1a of the vehicle floor carpet 1;
a backing resin layer 15 integrated with the back surface 10b of the carpet layer 10;
an additional resin layer 20 partially present on the back side of the backing resin layer 15,
The vehicle floor carpet 1 includes a general portion 30 without the additional resin layer 20 in a portion away from the opening OP1,
The additional resin layer 20 has a mode in which it exists on at least part of the periphery 38 of the opening OP1. This aspect also makes it possible to provide a vehicle floor carpet with enhanced rigidity while suppressing an increase in weight as much as possible.

Further, the present technology is a vehicle floor carpet 1 having a three-dimensional shape 2,
a carpet layer 10 arranged on the surface 1a of the vehicle floor carpet 1;
a backing resin layer 15 integrated with the back surface 10b of the carpet layer 10;
an additional resin layer 20 partially present on the back side of the backing resin layer 15,
The vehicle floor carpet 1 has a general portion 30 without the additional resin layer 20 in a portion apart from the edge portion 34 of the vehicle floor carpet 1 and a surface extending from the general portion 30 toward the edge portion 34 . and a rising wall portion 32,
The additional resin layer 20 has a mode in which it exists on at least part of the standing wall portion 32 . This aspect also makes it possible to provide a vehicle floor carpet with enhanced rigidity while suppressing an increase in weight as much as possible.

(7) Knot:
As described above, according to the present invention, there are provided, in various aspects, a vehicle floor carpet with increased rigidity while suppressing an increase in weight as much as possible, a manufacturing method suitable for manufacturing the vehicle floor carpet, and the like. can do. Of course, the above-described basic functions and effects can be obtained even with a technique consisting only of constituent elements according to independent claims (including aspects described in the embodiments).
In addition, a configuration in which each configuration disclosed in the above examples is replaced with each other or the combination thereof is changed, and each configuration disclosed in the known technology and the above example is replaced with each other or the combination thereof is changed. , etc. can also be implemented. The present invention also includes these configurations and the like.

1... Floor carpet, 1a... Front side, 1b... Back side,
1c... central concave portion, 1d... left portion, 1e... right portion, 1f... connection portion,
2, 2a, 2b... three-dimensional shape, 3, 3a, 3b... bending portion,
10... carpet layer, 10b... back surface,
15... backing resin layer, 15b... back surface, 18... vent hole,
20... Additional resin layer, 20b... Back surface, 25... Uneven shape, 26... Groove, 27... Ridge,
30... general part, 30a... front edge, 32... standing wall part, 34... edge part, 36... extension part, 38... circumference,
40, 41, 42 ... additional resin,
50... Original material,
60... Cushioning material layer, 60b... Back surface,
90... Automobile,
DESCRIPTION OF SYMBOLS 100... Carpet manufacturing apparatus, 110... Transfer machine,
120 to 125 ... supply section, 126 ... nozzle, 130 ... control section,
200... Press molding machine, 201... Upper mold, 202... Lower mold,
SL1... slit,
SP1... indoors,
ST1: additional resin supply step, ST2: molding step,
ST21...heating process, ST22...pressing process, ST23...cutting process,
D1... Front-back direction, D2... Left-right direction, D3... Thickness direction, D4... Transfer direction, D5... Width direction,
OP1, OP2, OP3 . . . openings.

Claims

A vehicle floor carpet having a three-dimensional shape and having an opening penetrating in the thickness direction,
a carpet layer disposed on the surface of the vehicle floor carpet;
a backing resin layer integrated with the back surface of the carpet layer;
an additional resin layer partially present on the back side of the backing resin layer,
The vehicle floor carpet includes a general portion without the additional resin layer in a portion away from the edge of the vehicle floor carpet and the opening, and a standing wall portion in which the surface rises from the general portion toward the edge. and
The vehicle floor carpet, wherein the additional resin layer is present around the opening and at least a part of the standing wall portion.
The vehicle floor carpet according to claim 1, wherein the additional resin layer exists on at least a portion of the periphery of the opening and on at least a portion of the standing wall portion.
The additional resin layer is present on at least part of the standing wall,
3. The vehicle floor carpet according to claim 1, wherein the additional resin layer present on the standing wall portion has an uneven surface on the back surface of the additional resin layer.
The vehicle floor carpet includes an outwardly extending portion at the edge,
The vehicle floor carpet according to any one of claims 1 to 3, wherein the additional resin layer is present on at least a part of the extending portion at the edge.
A method for manufacturing a vehicle floor carpet having a three-dimensional shape, comprising:
A width direction intersecting with the transfer direction in a state in which the base material including at least the carpet layer arranged on the surface of the vehicle floor carpet and the backing resin layer on the back surface of the carpet layer is transferred in the transfer direction. an additional resin supply step of partially supplying additional resin from the plurality of supply units onto the back surface of the base material while variably controlling the supply amounts of the plurality of supply units located at different positions in units of the supply units;
a molding step of molding the base material and the additional resin such that the additional resin layer partially existing on the back side of the backing resin layer is formed from the additional resin. Method.